TSG - Uenr4542-4

UENR4542-04 (en-us)
October 2017
Troubleshooting
2206–E13TA, 2206D-E13TA, 2506A-
E15TA, 2506C-E15TA, 2506D-E15TA,
2806C-E18TA, 2806D-E18TA and
2806D-E18TTA Industrial Engines
TGF (Engine)
PK3 (Engine)
JG (Engine)
PK5 (Engine)
PK8 (Engine)
MGA (Engine)
MGB (Engine)
TGB (Engine)
TGD (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
UENR4542-04 3
Table of Contents
Table of Contents Power Is Intermittently Low or Power Cutout Is

Intermittent...................................................... 121
Valve Lash Is Excessive .................................... 124
Troubleshooting Section Valve Rotator or Spring Lock Is Free................... 125
Introduction Circuit Tests

General Information ..............................................4 Air Shutoff - Test................................................ 127
Welding Precaution ...............................................4 CAN Data Link - Test ......................................... 136
Electronic Service Tools.........................................5 Coolant Level - Test........................................... 141
Cooling Fan Speed - Test................................... 146
Data Link - Test ................................................. 148
Electronic System Overview Electrical Power Supply - Test ............................ 152
System Overview ..................................................9 Ether Starting Aid - Test ..................................... 157
Component Location ........................................... 11 Indicator Lamp - Test ......................................... 162
Diagnostic Capabilities ........................................14 Injector Solenoid - Test ...................................... 165
Programmable Parameters ..................................15 Power Take-Off - Test ........................................ 173
Electrical Connectors ..........................................17 Retarder - Test .................................................. 179
Wiring Information ...............................................21 Sensor Calibration Required - Test ..................... 190
Sensor Signal (Analog, Active) - Test .................. 192
Configuration Parameters Sensor Signal (Analog, Passive) - Test ............... 201
Configuration Parameters ....................................22 Sensor Supply - Test (8 V Supply) ...................... 209
Sensor Supply - Test (5V Supply) ....................... 215
Diagnostic Trouble Codes Speed Control - Test.......................................... 222
Diagnostic Trouble Codes....................................29 Speed/Timing - Test .......................................... 224
Event Codes Service

Event Codes ......................................................38 Customer Passwords ........................................ 230
Factory Passwords............................................ 230
Symptom Troubleshooting ECM Will Not Accept Factory Passwords ............ 230
Symptom Troubleshooting ...................................45 Electronic Service Tool Does Not Communicate .. 231
Acceleration Is Poor or Throttle Response Is Poor .45 Test ECM Mode ................................................ 237
Alternator Problem ..............................................47 Injector Trim File - Install .................................... 238
Battery Problem ..................................................49 ECM Software - Install ....................................... 239
Boost Pressure Is High ........................................49 ECM - Replace ................................................. 240
Coolant Contains Fuel .........................................50 Electrical Connectors - Inspect ........................... 241
Coolant Contains Oil ...........................................51 Timing - Calibrate .............................................. 244
Coolant Level Is Low ...........................................54
Coolant Temperature Is High................................55 Index Section
Cylinder Is Noisy .................................................58
ECM Does Not Communicate with Other Modules .60
Engine Cranks but Does Not Start ........................61 Index................................................................ 250
Engine Does Not Crank .......................................63
Engine Has Early Wear........................................65
Engine Has Mechanical Noise (Knock) .................67
Engine Misfires, Runs Rough or Is Unstable..........70
Engine Overspeeds.............................................72
Engine Shutdown Occurs Intermittently ................74
Engine Stalls at Low RPM....................................76
Engine Top Speed Is Not Obtained .......................78
Engine Vibration Is Excessive ..............................81
Exhaust Has Excessive Black Smoke ...................82
Exhaust Has Excessive White Smoke...................84
Exhaust System Contains Oil ...............................87
Exhaust Temperature Is High ...............................88
Fuel Consumption Is Excessive............................92
Fuel Pressure Is High ..........................................94
Fuel Pressure Is Low ...........................................99
Fuel Temperature Is High................................... 103
Inlet Air Temperature Is High .............................. 109
Intake Manifold Air Temperature Is High.............. 111
Oil Consumption Is Excessive ............................ 112
Oil Contains Coolant ......................................... 114
Oil Contains Fuel .............................................. 117
Oil Pressure Is Low ........................................... 118
4 UENR4542-04
Introduction
Troubleshooting Section Fault Detection and Reporting

The ECM monitors inputs from the sensors and
inputs from the applications control system. Software
in the ECM interprets the inputs. The software
Introduction determines if the inputs are operating correctly. A
diagnostic trouble code is activated when the
software detects a problem with an input.
The ECM broadcasts the codes on two data links.
i05957486 The data links are the Perkins Data Link (PDL) and
J1939 CAN data link. The electronic service tool
General Information must communicate on both data links in order to
service the engine. If a problem is suspected with
one of the data links, refer to Troubleshooting, “Data
Link - Test” or Troubleshooting, “CAN Data Link -
Test”.
Overview
The codes can be displayed on the electronic service
These engines are equipped with an electronic tool and optional operator interfaces.
control system. The system consists of a computer,
sensors, and software. The system provides these Troubleshooting
capabilities:
As a reference, simplified schematics for each of the
• Control of the engine engines subsystems are included with each of the
circuit tests that are in this manual. For an accurate
• Applications control system interface representation of the entire electrical schematic that
is for your application, refer to the Electrical System
• Fault detection and reporting Schematic.
Electronic Control System During troubleshooting, inspect all harness

connections before any component is replaced. If
The Electronic Control Module (ECM) is a computer these connections are not clean and tight, continuous
that controls the operation of the engine. electrical problems or intermittent electrical problems
can result. Check that the wires are pushed into the
The ECM contains a flash file. The flash file is the connectors completely. Make sure that the
software for the ECM. The flash file contains the connections are tight before other tests are made.
operating maps. The operating maps define the
following characteristics of the engine: Failure of an electrical component may cause the
failure of other components. Always attempt to
• Horsepower correct the cause of an electrical failure before you
replace a component. If wire insulation is punctured,
• Torque curves repair the damage.
• Engine speed (rpm)
Refer to Troubleshooting, “System Overview” for i05957501
additional information on the electronic control
system.
Welding Precaution
Application Interface
The ECM interfaces with the machine via software
and an electrical connector on the ECM. The Proper welding procedures are necessary in
software can be configured. order to avoid damage to the engine Electronic
Control Module (ECM), to the Clean Emissions
The applications control system provides inputs to Module (CEM), if equipped, to sensors, and to
the electrical connector on the ECM in order to associated components. Also consider
indicate the status of switches. Configure the ECM in components that are for the driven equipment.
order to interpret the inputs. Remove the component that requires welding.
When welding on an engine that is equipped with
The ECM provides outputs for the applications an ECM and removal of the component is not
control system via the electrical connector in order to possible, the following procedure must be
control lamps, solenoids, and other devices. followed. This procedure provides the minimum
Configure the ECM to match the configuration of the amount of risk to the electronic components.
applications control system.
1. Stop the engine. Remove the electrical power from
the ECM.
UENR4542-04 5
Introduction
2. Ensure that the fuel supply to the engine is turned 7. Use standard welding procedures to weld the
off. materials together.
3. Disconnect the negative battery cable from the
i05957511
battery. If a battery disconnect switch is installed,
open the switch.
Electronic Service Tools
4. Disconnect all electronic components from the
wiring harnesses. Electronic components include
the following components:
Service Tools
• Electronic components for the driven Most of the tools that are listed in Table 1 are
equipment required to enable a service technician to perform the
test procedures in this manual. Some of the devices
• The engine ECM may be specific to the type of Electronic Control
Module (ECM) that is being used.
• Sensors Table 1
Service Tools
NOTICE
Do NOT use electrical components (ECM or sensors) Part Description
or electronic component grounding points for ground- Number
ing the welder.
N/A 4 mm Allen Wrench
28170079 Wedge Removal Tool
T400920 Wire Removal Tool (14-GA TO 18-GA, RED)
CH11155 Crimp Tool (12−AWG TO 18−AWG)
GE50038 Transducer
GE50039 Transducer Adapter
GE50040 Cable As
CVT0019 Adapter Cable As (3-PIN BREAKOUT)
T400922 Adapter Cable As (40-PIN BREAKOUT)

T400923 Harness (40-PIN)
(For ADEM 2 ECM (two 40-pin connectors))
GE50037 / Adapter Cable As (70-PIN BREAKOUT)

2900A025 (For ADEM 3 ECM (two 70-pin connectors) and
for ADEM 4 ECM (one 70-pin connector and one
120-pin connector))
T400924 Adapter Cable As (120-PIN BREAKOUT)

(For ADEM 4 ECM (one 70-pin connector and one
120-pin connector))
Illustration 1 g01143634 N/A Torque Wrench (capable of applying 1.5 N·m

(13.3 lb in))
Service welding guide (typical diagram)
Repair Kits for Connectors
5. When possible, connect the welder ground clamp
U5MK1110 Connector Repair Kit (AMPSEAL)
directly to the engine component that will be
welded. Place the clamp as close as possible to U5MK8194 Connector Repair Kit (Deutsch connector )
the weld. A close connection will reduce the
Bypass Harnesses for the ECM
possibility of welding current damage to the engine
bearings, to the electrical components, and to T400925 Power Cable
other components. (Stand alone cable for ADEM 2 ECM)
6. Protect the wiring harnesses from welding debris

and/or from the welding spatter. (continued)
6 UENR4542-04
Introduction
(Table 1, contd) • Programming of flash file

Service Tools
• Parameter programming
Part Description
Number • Copy configuration function for Electronic Control
Module (ECM) replacement
2900A038 Wiring Harness (ECM BYPASS)
(The bypass harness connects to the battery. The • Data logging
bypass harness is used with the following har-
nesses for different types of electronic control • Graphs (real time)
modules.)
T400926 Harness (ENGINE ECM BYPASS)

Table 3 lists the service tools that are required in
(For ADEM 3 ECM and ADEM 4 ECM)
order to use the Electronic Service Tool.
Table 3
28170107 Harness (ENGINE ECM BYPASS)
Service Tools for the Use of the Electronic Service
(For A4:E2 ECM (Two 64-pin connectors))
Tool
Part Number Description

Two short jumper wires may be needed to check the
continuity of some wiring harness circuits by shorting -(1) Single Use Program License
two adjacent terminals together in a connector. A
long extension wire may also be needed to check the -(1) Data Subscription for All Engines
continuity of some wiring harness circuits.
27610164 TIPSS Adapter Kit (Electronic Service Tool to
the ECM interface)
Optional Service Tools or
Table 2 lists the optional service tools that may be 27610401 Perkins CA3 Kit
needed during testing or repair. (1) Refer to Perkins Engine Company Limited.
Table 2
Note: For more information on the Electronic Service
Tool and the PC requirements, refer to the
U5MK1092 Spoon Probe Kit (MULTIMETER) documentation that accompanies the software for the
Electronic Service Tool.
- Suitable Digital Pressure Indicator
or or
- Engine Pressure Group
- Suitable Battery Load Tester
- Suitable Temperature Adapter

(MULTIMETER)
2900A038 Harness as
Perkins Electronic Service Tool

The Electronic Service Tool can display the following
information:
• Status of all pressure sensors and temperature
sensors
• Programmable parameter settings

• Active diagnostic codes and logged diagnostic
codes
• Logged events
• Histograms
The Electronic Service Tool can also be used to
perform the following functions:
• Diagnostic tests
• Calibrations
UENR4542-04 7
Introduction
Connecting the Electronic Service Tool 4. Place the keyswitch in the ON position. If the
and the TIPSS Adapter Electronic Service Tool and the TIPSS adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
Connecting the Electronic Service Tool

and the CA3 Kit
Illustration 2 g03738342
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) TIPSS adapter
(4) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the TIPSS
adapter kit.
Use the following procedure in order to connect the
(1) Personal Computer (PC)
Electronic Service Tool and the TIPSS Adapter. (2) Adapter Cable (Computer Serial Port)
(3) CA3 adapter
1. Turn the keyswitch to the OFF position. (4) Adapter Cable Assembly
2. Connect cable (2) between the “COMPUTER” end
of TIPSS adapter (3) and the RS232 serial port of Note: Items (2), (3) and (4) are part of the CA3 kit.
PC (1). Use the following procedure in order to connect the
Electronic Service Tool and the CA3 Adapter.
Note: The Adapter Cable Assembly (4) is required to
connect to the USB port on computers that are not 1. Turn the keyswitch to the OFF position.
equipped with an RS232 serial port.
2. Connect cable (2) between the “COMPUTER” end
3. Connect cable (4) between the “DATA LINK” end of CA3 adapter (3) and a USB port of PC (1).
of TIPSS adapter (3) and the service tool
3. Connect cable (4) between the “DATA LINK” end
connector.
of CA3 adapter (3) and the service tool connector.
8 UENR4542-04
Introduction
4. Place the keyswitch in the ON position. If the

Electronic Service Tool and the CA3 adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
UENR4542-04 9
Electronic System Overview
Electronic System • Reduced warm-up time
Overview • Reduced white smoke

Cold mode is activated whenever the engine
temperature falls below a predetermined value. Cold
mode remains active until the engine temperature
rises above a predetermined value or until a time limit
i06299999
is exceeded.
System Overview Fuel Injection
The ECM controls the amount of fuel that is injected
by varying the signals to the injectors. The injector
System Operation will pump fuel only if the injector solenoid is
energized. The ECM sends a high voltage signal to
This engine is electronically controlled. Each cylinder
the solenoid. This high voltage signal energizes the
has an electronic unit injector. The Electronic Control
solenoid. By controlling the timing and the duration of
Module (ECM) sends a signal to each injector
the high voltage signal, the ECM can control injection
solenoid in order to control the operation of the fuel
timing and the engine RPM.
injection system.
The flash file inside the ECM sets certain limits on the
Electronic Controls amount of fuel that can be injected. The “FRC Fuel
Limit” is used to control the air/fuel ratio for control of
The electronic system consists of the following emissions. The “FRC Fuel Limit” is a limit that is
components: the ECM, the Mechanically Actuated based on the turbocharger outlet pressure. A higher
Electronically Controlled Unit Injectors (MEUI), the turbocharger outlet pressure indicates that there is
wiring harness, the switches and the sensors. The more air in the cylinder. When the ECM senses a
ECM is the computer. The flash file is the software for higher turbocharger outlet pressure, the ECM
the computer. The flash file contains the operating increases the “FRC Fuel Limit” . When the ECM
maps. The operating maps define the following increases the “FRC Fuel Limit” , the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
characteristics of the engine: programmed into the ECM at the factory. The “FRC
Fuel Limit” cannot be changed.
• Horsepower
The “Rated Fuel Limit” is a limit that is based on the
• Torque curves power rating of the engine and on engine rpm. The
“Rated Fuel Limit” is similar to the rack stops and to
The ECM determines the timing and the amount of the torque spring on a mechanically governed
fuel that is delivered to the cylinders. These decisions engine. The “Rated Fuel Limit” provides the power
are based on the actual conditions and/or on the curves and the torque curves for a specific engine
desired conditions at any given time.
family and for a specific engine rating. The “Rated
The ECM compares the desired engine speed to the Fuel Limit” is programmed into the ECM at the
actual engine speed. The actual engine speed is factory. The “Rated Fuel Limit” cannot be changed.
determined through a signal from the engine speed/
timing sensor. The desired engine speed is Once the ECM determines the amount of fuel that is
required, the ECM must determine the timing of the
determined with the following factors: fuel injection. The ECM calculates the TOP CENTER
position of each cylinder from the engine speed/
• Throttle signal timing sensor signal. The ECM decides when fuel
• Other input signals from sensors injection should occur relative to the top center
position and the ECM provides the signal to the
• Certain diagnostic codes injector at the desired time. The ECM adjusts timing
for optimum engine performance, for optimum fuel
If the desired engine speed is greater than the actual economy, and for optimum control of white smoke.
engine speed, the ECM injects more fuel in order to
increase the actual engine speed. Programmable Parameters
Certain parameters that affect the engine operation
Cold Mode may be changed with the electronic service tool. The
parameters are stored in the ECM, and some
The ECM limits engine power during cold mode parameters are protected from unauthorized changes
operation and the ECM modifies injection timing by passwords. These passwords are called factory
during cold mode operation. Cold mode operation passwords.
provides the following benefits:
• Increased cold weather starting capability

10 UENR4542-04
Passwords
Several system configuration parameters and most
logged events are protected by factory passwords.
Factory passwords are available only to Perkins
distributors. Refer to Troubleshooting, “Factory
Passwords” for additional information.
UENR4542-04 11
i06605777
Component Location
12 UENR4542-04
UENR4542-04 13
2206D Engines
Locations of the sensors on 2206D engines
(1) Engine coolant temperature sensor (4) Fuel pressure sensor (7) Fuel temperature sensor
(2) Atmospheric pressure sensor (5) Engine oil pressure sensor (8) Intake manifold air temperature sensor
(3) Secondary engine speed/timing sensor (6) Boost pressure sensor (9) Primary engine speed/timing sensor
14 UENR4542-04
2506 and 2806D Engines
Locations of the sensors on 2506 and 2806D engines
(1) Engine coolant temperature sensor (4) Fuel pressure sensor (7) Engine oil pressure sensor
(2) Secondary engine speed/timing sensor (5) Fuel temperature sensor (8) Atmospheric pressure sensor
(3) Boost pressure sensor (6) Intake manifold air temperature sensor (9) Primary engine speed/timing sensor
i05957583 Event Code – An event code is generated by the

detection of an abnormal engine operating condition.
Diagnostic Capabilities For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
indicates the symptom of a problem. Generally, event
codes indicate abnormal operating conditions or
mechanical problems rather than electrical problems.
Diagnostic Codes
The engines Electronic Control Module (ECM) can Codes can have two different states:
monitor the circuitry between the ECM and the
engines components. The ECM can also monitor the • Active
engines operating conditions. If the ECM detects a
problem, a code is generated. • Logged
There are two categories of codes:
Active Codes
• Diagnostic code
An active code indicates that a problem is present.
• Event code Service the active code first. For the appropriate
troubleshooting procedure for a particular code, refer
Diagnostic Code – A diagnostic code indicates an to the appropriate troubleshooting procedure.
electrical problem such as a short circuit or an open
circuit in the engines wiring or in an electrical
component.
UENR4542-04 15
Logged Codes active but the code may become logged.
The codes are logged and stored in the ECM Logged codes may not indicate that a repair is
memory. The problem may have been repaired and/ needed. The problem may have been temporary.
or the problem may no longer exist. If the system is Logged codes may be useful to help troubleshoot
powered, an active diagnostic code may be intermittent problems. Logged codes can also be
generated whenever a component is disconnected. If used to review the performance of the engine and of
the component is reconnected, the code is no longer the electronic system.
i06534836
Programmable Parameters
Table 4
Diagnostic Trouble Codes
J1939 Code Code Description

(code descriptions may
PDL Code vary) Comments
The Electronic Control Module (ECM) detects one of the following
conditions:
· One or more of the programmable parameters have not been

programmed
Engine Protection System · One or more of the injector trim files are not programmed.
630-2 268-2 Configuration : Erratic, Inter-
mittent, or Incorrect The diagnostic code will only be active. The check engine lamp is il-
luminated when this diagnostic code is active.
Engine performance may be affected by unprogrammed parame-
ters. The unprogrammed parameters determine the action that is
taken by the ECM. The ECM may use a default torque map or the
ECM may limit the engine to low idle.
Programming Parameters When the “Test ECM Mode” is activated, an internal

timer sets a 24-hour clock. This clock will count down
The electronic service tool can be used to view only when the ECM is powered. If the new ECM fixes
certain parameters that can affect the operation of the problem, the engine can be released whilst the
the engine. The electronic service tool can also be “Test ECM Mode” is still active. After the ECM has
used to change certain parameters. The parameters counted down the 24-hour period, the ECM will exit
are stored in the Electronic Control Module (ECM). the “Test ECM Mode” . The parameters, the
Some of the parameters are protected from accumulated hours, and the engine serial number will
unauthorized changes by passwords. Parameters be permanently programmed into the new ECM. The
that can be changed have a tattletale number. The new ECM can no longer be used for another engine
tattletale number shows if a parameter has been or for a test ECM.
changed.
Note: When the “Test ECM Mode” is activated, the
Test ECM Mode “Personality Module Code” is 0. After the ECM has
“Test ECM Mode” is a feature on the electronic counted down the 24-hour period, the “Personality
service tool that is used to troubleshoot an engine Module Code” depends on the application.
that may have a problem with the Electronic Control
Module (ECM). If the new ECM does not resolve the problem, and 24
hours has not expired, the ECM can be used as a
If an application supports this feature, the electronic new ECM. Anytime prior to the 24-hour limit of the
service tool will allow a new ECM to be used “Test ECM Mode” , a new engine serial number and
temporarily as a test ECM. If an application does not new parameters can be reprogrammed.
support this feature, refer to Troubleshooting, “ECM -
Replace”. 1. Search for the latest flash file for the engine.
Note: If a newer software version is available for the
engine, install the newest software on the suspect
ECM. If the new software does not fix the problem,
continue with this procedure.
16 UENR4542-04
2. Use the “Copy Configuration/ECM Replacement” If the problem is resolved with the new ECM,
feature on the electronic service tool to copy the remove the original ECM and permanently install
configuration parameters from the suspect ECM to the new ECM.
your personal computer (PC). If the “Copy If the new ECM does not fix the problem, the
Configuration/ECM Replacement” feature cannot original ECM is not the problem. Remove the new
be used, record the programmed values into the ECM before the 24-hour timer expires. Reconnect
“Parameters Worksheet” in system configuration the original ECM.
parameters Troubleshooting, “System
Configuration Parameters”. Record the injector Flash Programming
serial numbers from the “Calibrations” screen Flash Programming – Flash programming is a
under the “Service” menu on the electronic service method of programming or updating the flash file in
tool. an Electronic Control Module (ECM).
Note: Some applications use injectors that have trim The electronic service tool is utilized to flash program
codes or injector trim files that are associated with a flash file into the ECM. The flash programming
the injectors. If injector trim codes are necessary, the transfers the flash file from the PC to the ECM.
injector trim codes are printed on the injector. If
injector trim files are necessary, the injector serial Flash Programming a Flash File
numbers are necessary for obtaining the correct 1. Obtain the part number for the new flash file.
injector trim files from the electronic service tool. The
injector trim file is a number that is specific to each Note: If you do not have the part number for the flash
unit injector. The ECM uses this number to file, use “PTMI” on the Perkins secured web site.
compensate for manufacturing variations between
individual injectors. If any of the injectors are Note: You must have the engine serial number to
replaced, the injector trim files must be programmed search for the part number of the flash file.
for the new injectors. Also, if the ECM is replaced, all
the injector trim files must be programmed into the 2. Connect the electronic service tool to the
new ECM. diagnostic connector.
3. Disconnect the suspect ECM. Temporarily connect 3. Turn the keyswitch to the ON position. Do not start
the new ECM to the engine. Do not mount the new the engine.
ECM on the engine. 4. Select “WinFlash” from the “Utilities” menu on the
4. Program the correct flash file into the new ECM. electronic service tool.
Note: The “Test ECM Mode” must be activated Note: If “WinFlash” will not communicate with the
before the engine serial number is programmed into ECM, refer to Troubleshooting, “Electronic Service
the new ECM. “Test ECM Mode” can only be Tool Does Not Communicate”.
activated if the engine serial number has not already
been programmed during normal operation of the 5. Flash program the flash file into the ECM.
ECM. A new ECM can never be used as a test ECM
after the engine serial number is programmed. a. Select the engine ECM under the “Detected
ECMs” .
5. Start the “Test ECM Mode” on the electronic
b. Press the “Browse” button to select the part
service tool. Access the feature through the
number of the flash file that will be programmed
“Service” menu. The electronic service tool will
into the ECM.
display the status of the “Test ECM Mode” and the
hours that are remaining for the “Test ECM Mode” c. When the correct flash file is selected, press the
. “Open” button.
Note: If the “Copy Configuration/ECM Replacement” d. Verify that the “File Values” match the
feature cannot be used, program the values from the application. If the “File Values” do not match the
“Parameters Worksheet” . application, search for the correct flash file.
6. Use the “Copy Configuration/ECM Replacement” e. When the correct flash file is selected, press the
feature on the electronic service tool to program “Begin Flash” button.
the correct parameters into the new ECM.
f. The electronic service tool will indicate when
7. Program the engine serial number into the new
flash programming has been successfully
ECM.
completed.
UENR4542-04 17
6. Access the “Configuration” screen under the “ WinFlash”” Error Messages

“Service” menu to determine the parameters that
require programming. If any error messages are displayed during flash
programming, click the “Cancel” button to stop the
7. Start the engine and check for proper operation. process. Access the information about the “ECM
Check that there are no active diagnostic codes. Summary” under the “Information” menu. Ensure that
you are programming the correct flash file for your
engine.
i06605858
Electrical Connectors
18 UENR4542-04
Connectors for the Electronic Control

Module (ECM)
Locations of the components at the Engine ECM
(1) P2 ECM connector (ECM side) (3) P2 ECM connector (harness side) (5) Engine ECM
(2) P1 ECM connector (ECM side) (4) P1 ECM connector (harness side)
UENR4542-04 19
Injector Connectors Sensor Connectors

Connectors at the Valve Cover Analog Sensor Connector (active)
Illustration 8 g01746753 Illustration 10 g01240891
Connector at the Injector Analog Sensor Connector (passive)
Typical HD injector
20 UENR4542-04
Connectors for the Termination Resistor Ampseal Connector (typical)
Engine Speed/Timing Connector
UENR4542-04 21
Deutsch Connectors (typical) Table 5

Color Codes for the Harness Wire
Color Code Color Color Code Color
BK Black GN Green
BR Brown BU Blue
RD Red PU Purple
OR Orange GY Gray
YL Yellow WH White
PK Pink
For example, a wire identification of A701-GY(Grey)

on the schematic would signify a gray wire with the
circuit number A701. A701-GY(Grey) identifies the
power circuit for the No. 1 Injector solenoid.
i05958935
Wiring Information
The connection of any electrical equipment and

the disconnection of any electrical equipment
may cause an explosion hazard which may result
in injury or death. Do not connect any electrical
equipment or disconnect any electrical equip-
ment in an explosive atmosphere.
The wiring schematics are revised periodically. The
wiring schematics will change as updates are made
to the engine harness. For the most current
information, always check the revision number of the
schematic. Use the schematic with the latest revision
number.
Harness Wire Identification

Wires are identified with 11 solid colors. The circuit
number is stamped on the wire at a 25 mm (1 inch)
spacing. Table 5 lists the wire colors and the color
codes.
22 UENR4542-04
Configuration Parameters
Configuration Parameters “ Top Engine Limit”” (TEL)
i06300016
System configuration parameters are parameters

that affect the emissions and the power of the engine.
Default values for the parameters are programmed at
the factory. Some parameters may be changed by
the customer in order to suit the needs of the specific
application.
Parameter Descriptions
“ Equipment ID””
“Equipment ID” allows the customer to enter a
description into the Electronic Control Module (ECM)
in order to identify the machine. A maximum of 17 Illustration 16 g00763900
characters may be entered in the field. This
parameter is only for reference by the customer. This “TEL” is a customer programmable parameter that
parameter is not required. defines the maximum allowable engine speed for
maximum power. “TEL” can be programmed up to
the maximum rated engine speed. “TEL” is defined
“ Engine Serial Number”” along the engine's lug curve.
Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine Programming the “ Top Engine Limit””
information plate. If the ECM is replaced, the engine
serial number from the engine information plate must In certain instances, the “TEL” must be programmed
be programmed into the new ECM. using the procedure outlined below.
Note: When you are requesting factory passwords,

always use the engine serial number that is
programmed in the ECM.
“ Rating Number””
The “Rating Number” corresponds to the selected set
of performance maps for the application. This
selected set of performance maps comes out of
several unique sets of maps that are resident in the
flash file. The dealer and/or the OEM will need to
select the appropriate rating tier, if more than one
rating tier is present. The rating tiers are “A” through
“E” .
Note: Factory passwords are required in order to

change the “Rating Number” .
UENR4542-04 23
1. Program “Run Out Control” to “ON” , then

disconnect from the electronic service tool and
completely remove battery power from the ECM.
24 UENR4542-04
2. Restore the power. After power is restored,

program “Run Out Control” to “ON” . “Top Engine
Limit” is now “2100 RPM” instead of “Unavailable”
.
3. Program “Top Engine Limit” to “1800 RPM” .

Program “High Idle Speed” to “1800 RPM” .
UENR4542-04 25
“ Engine Accel. Rate”” “ Intermediate Engine Speed””

“Engine Accel. Rate” determines the rate of change “Intermediate Engine Speed” defines the speed for
of the engine speed (acceleration or deceleration) the engine when the intermediate engine speed
during PTO operation. This rate of change is also switch is activated. This parameter can be
used to achieve intermediate engine speed. programmed to any engine speed between “Low Idle
Speed” and “TEL” . Engine speed will increase or
“ Low Idle Speed”” engine speed will decrease at the rate that is defined
by the programmed value for “Engine Accel. Rate” .
“Low Idle Speed” is the minimum allowable operating
speed for the engine. This parameter can be “ Maximum Engine Torque Limit””
programmed between 600 and 1400 rpm.
“ PTO Mode””
“PTO Mode” allows the ECM to be programmed to
either one of the two PTO configurations that are
available.
“ Ramp Up/Ramp Down”” – When “PTO Mode” is
programmed to “Ramp Up/Ramp Down” , the ECM
allows PTO operation with traditional features.
“ Set/Resume”” – When “PTO Mode” is programmed
to “Set/Resume” , the ECM allows PTO operation
with enhanced features.
“ High Idle Speed””
“Engine Torque Limit” can be used to limit torque

output to the programmed value when the torque limit
switch is activated.
“ FLS”” (Full Load Setting)

“FLS” is a number that represents the adjustment to
the fuel system that was made at the factory in order
to fine-tune the fuel system. The correct value for this
parameter is stamped on the engine information
plate. Factory passwords are required in order to
change this parameter.
“ FTS”” (Full Torque Setting)
Illustration 20 g00763900 “FTS” is similar to “FLS” . Factory passwords are

required in order to change this parameter.
“High Idle Speed” is the maximum no-load engine
speed when the throttle or the PTO switch is in the “ Ether Control””
maximum position.
Program the “Ether Control” to “Enabled” if an ether
Note: “High Idle Speed” cannot be programmed injection system is installed on the engine. This
lower than “TEL” . action allows the ECM to control ether injection. If the
engine is not equipped with ether, program this
parameter to “Disabled” .
26 UENR4542-04
“ Air Shutoff”” “ Aux Temp Sensor Installation Status””

“Air Shutoff” allows the ECM to be programmed for Program “Aux Temp Enable” to “Installed” if an
operation of an air shutoff system. If this parameter is auxiliary temperature sensor is installed. This action
programmed to “Installed” , the ECM will activate the will allow the Perkins Messenger Driver Information
air shutoff solenoid in the event of an engine Display to monitor the temperature of another
overspeed condition. system. Program this parameter to “Not Installed” if
an auxiliary temperature sensor is not installed.
Note: If an engine overspeed condition occurs and
“Air Shutoff” is programmed to “Enabled” , the
switched power to the ECM must be cycled and the
air shutoff solenoid must be manually reset before
the engine will restart.
“ Maintenance Indicator Mode””

The ECM records data that is related to equipment
maintenance. The ECM will activate the maintenance
indicator lamp when scheduled maintenance is due.
The maintenance indicator lamp can be reset by
actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or on fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.
“ PM1 Interval””
“PM1 Interval” allows the customer to define the
maintenance interval if “Maintenance Indicator Mode”
is programmed to one of the manual options. Refer to
the engine's Operation and Maintenance Manual for
more information.
“ Throttle Position Sensor””

Program the “Throttle Position Sensor” to “Installed” if
a throttle position sensor is used for desired speed
control. Otherwise program this parameter to “Not
Installed” .
“ Coolant Level Sensor””

Program the “Coolant Level Sensor” to “Installed” if a
coolant level sensor is installed on the engine.
Otherwise program this parameter to “Not Installed” .
“ Aux Press Sensor Installation Status””

Program “Aux Press Enable” to “Installed” if an
auxiliary pressure sensor is installed. This action will
allow the Perkins Messenger Driver Information
Display to monitor the pressure of another system.
Program this parameter to “Not Installed” if an
auxiliary pressure sensor is not installed.
UENR4542-04 27
System Configuration Parameters

Table 6
Available Range or Options Required

Parameter Default
Password
ECM Identification Parameters
“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None
“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None
“ECM Serial Number” “Read Only” (1)
“Software Gp Part Number” Software Dependent Read Only (1)
“Software Gp Release Date” Software Dependent Read Only (1)
Selected Engine Rating
“Rating Number” Software Dependent Customer
“Rated Power” Software Dependent Read Only (1)
“Rated Peak Torque” Software Dependent Read Only (1)
“Top Engine Speed Range” Software Dependent Read Only (1)
“Test Spec” Software Dependent Read Only (1)
“Top Engine Limit” Software Dependent Customer
“Speed Control”
“Engine Governor Primary Mode” “Speed Control” None
“Min/Max”
“Engine Accel. Rate” 50 to 1000 50 None
“Low Idle Speed” 600 to 1400 700 None
“Ramp Up/Ramp Down”

“PTO Mode” “Ramp Up/Ramp Down” None
“Set/Resume”
“High Idle Speed” 1800 to 2310 2310 Customer
“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None
“Maximum Engine Torque Limit” Software Dependent None
“Customer Password #1” 8 alphanumeric characters Blank Customer
“Customer Password #2” 8 alphanumeric characters Blank Customer
“FLS” (Full Load Setting) - 128 to 127 0 Factory
“FTS” (Full Torque Setting) -128 to 127 0 Factory
“No Ether”
“Ether Control” “No Ether” None
“Continuous Flow”
“Enabled”
“Air Shutoff” “Disabled” None
“Disabled”
“OFF”
“Auto Fuel”
“Maintenance Indicator Mode” “Auto Hour” “OFF” None
“Man Fuel”
“Man Hour”
(continued)
28 UENR4542-04
(Table 6, contd)
Available Range or Options Required

Parameter Default
Password
100 to 750 Hours 250 Hours
“PM1 Interval” or or None
3785 to 28390 L (1000 to 7500 US gal) 9463 L (2500 US gal)
“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Installed”
“Coolant Level On” “Not Installed” None
“Not Installed”
“Last Tool to change Customer
Read Only (1)
Parameters”
“Last Tool to change System
Read Only (1)
Parameters”
“On”
“Aux Temp Sensor Installation Status” “Off” None
“Off”
“Aux Press Sensor Installation “On”
“Off” None
Status” “Off”
“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.
UENR4542-04 29
i06923808
Diagnostic Trouble Codes in J1939

Order
Table 7 lists the diagnostic trouble codes that apply to
the engine. The codes are listed in J1939 order. Use
the electronic service tool to determine the codes that
are active or logged. Then refer to the appropriate
troubleshooting procedure for more information.
Table 7
List of Diagnostic Trouble Codes
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
91–3 91–3 Troubleshooting, “Speed Control - Test”

Accelerator Pedal Position #1 : Voltage Above Throttle Position Sensor : Voltage Above
Normal Normal
Accelerator Pedal Position #1 : Voltage Below Throttle Position Sensor : Voltage Below
Normal Normal
Accelerator Pedal Position #1 : Abnormal Fre- Throttle Position Sensor : Abnormal Fre-
quency, Pulse Width or Period quency, Pulse Width, or Period
94–3 94–3 Troubleshooting, “Sensor Signal (Analog, Ac-

Engine Fuel Delivery Pressure : Voltage Above Fuel Delivery Pressure Sensor : Voltage tive) - Test”
Normal Above Normal
Engine Fuel Delivery Pressure : Voltage Below Fuel Delivery Pressure Sensor : Voltage Below tive) - Test”
Normal Normal
94–13 94–13 Troubleshooting, “Sensor Calibration Required
Engine Fuel Delivery Pressure : Out of Fuel Delivery Pressure Sensor : Out of - Test”
Calibration Calibration
Engine Oil Pressure : Voltage Above Normal Engine Oil Pressure Sensor : Voltage Above tive) - Test”
Normal
Engine Oil Pressure : Voltage Below Normal Engine Oil Pressure Sensor : Voltage Below tive) - Test”
Normal
100–10 100–10 Troubleshooting, “Sensor Supply - Test (5V
Engine Oil Pressure : Abnormal Rate of Engine Oil Pressure Sensor : Abnormal Rate Supply)”
Change of Change

Engine Oil Pressure : Out of Calibration Engine Oil Pressure Sensor : Out of - Test”
Calibration
(continued)
30 UENR4542-04
(Table 7, contd)
Engine Intake Manifold #1 Pressure : Abnor- Intake Manifold Pressure Sensor : Abnormal Supply)”
mal Rate of Change Rate of Change
105–3 172–3 Troubleshooting, “Sensor Signal (Analog, Pas-

Engine Intake Manifold #1 Temperature : Volt- Intake Manifold Air Temperature Sensor : Volt- sive) - Test”
age Above Normal age Above Normal

Engine Intake Manifold #1 Temperature : Volt- Intake Manifold Air Temperature Sensor : Volt- sive) - Test”
age Below Normal age Below Normal

Barometric Pressure : Voltage Above Normal Atmospheric Pressure Sensor : Voltage Above tive) - Test”
Normal
Barometric Pressure : Voltage Below Normal Atmospheric Pressure Sensor : Voltage Below tive) - Test”
Normal
Engine Coolant Temperature : Voltage Above Engine Coolant Temperature Sensor : Voltage tive) - Test”
Normal Above Normal
Engine Coolant Temperature : Voltage Below Engine Coolant Temperature Sensor : Voltage tive) - Test”
Normal Below Normal
168–0 168–0 Troubleshooting, “Electrical Power Supply -
Battery Potential / Power Input #1 : High - most Electrical System Voltage : High Test”
severe (3)

Battery Potential / Power Input #1 : Low - most Electrical System Voltage : Low Test”
severe (3)
168-2 168-2 Troubleshooting, “Electrical Power Supply -

Battery Potential / Power Input #1 : Erratic, In- Electrical System Voltage : Erratic, Intermit- Test”
termittent, or Incorrect tent, or Incorrect

Battery Potential / Power Input #1 : Voltage Electrical System Voltage : Voltage Above Test”
Above Normal Normal
Battery Potential / Power Input #1 : Voltage Electrical System Voltage : Voltage Below Test”
Below Normal Normal
Engine Fuel Temperature 1 : Voltage Above Fuel Temperature Sensor : Voltage Above sive) - Test”
Normal Normal
Engine Fuel Temperature 1 : Voltage Below Fuel Temperature Sensor : Voltage Below sive) - Test”
Normal Normal
190–8 190–8 Troubleshooting, “Speed/Timing - Test”
Engine Speed : Abnormal Frequency, Pulse Engine Speed Sensor : Abnormal Frequency,
Width, or Period Pulse Width, or Period

Auxiliary Temperature #1 : Voltage Above Auxiliary Temperature Sensor : Voltage Above sive) - Test”
Normal Normal
Auxiliary Temperature #1 : Voltage Below Auxiliary Temperature Sensor : Voltage Below sive) - Test”
Normal Normal
(continued)
UENR4542-04 31
(Table 7, contd)
626-5 2417-5 Troubleshooting, “Ether Starting Aid - Test”
Engine Start Enable Device 1 : Current Below Ether Injection Control Solenoid : Current Be-
Normal low Normal
Engine Start Enable Device 1 : Current Above Ether Injection Control Solenoid : Current
Normal Above Normal
630-2 268-2 Troubleshooting, “Programmable Parameters”
Calibration Memory : Erratic, Intermittent, or Programmed Parameter Fault : Erratic, Inter-
Incorrect mittent, or Incorrect
631–2 253–2 Troubleshooting, “ECM Software - Install”

Calibration Module : Erratic, Intermittent, or Personality Module : Erratic, Intermittent, or
Incorrect Incorrect
637–11 261–11 Troubleshooting, “Timing - Calibrate”
Engine Timing Sensor : Other Failure Mode Engine Timing Offset fault

Engine Timing Sensor : Out of Calibration Engine Timing Calibration : Out of Calibration
639–9 247–9 Troubleshooting, “CAN Data Link - Test”

J1939 Network #1 : Abnormal Update Rate SAE J1939 Data Link : Abnormal Update Rate
651–5 1–5 Troubleshooting, “Injector Solenoid - Test”

Engine Injector Cylinder #01 : Current Below Cylinder #1 Injector : Current Below Normal
Normal
Engine Injector Cylinder #01 : Current Above Cylinder #1 Injector : Current Above Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
(continued)
32 UENR4542-04
(Table 7, contd)
Normal
ECU 8 Volts DC Supply : Voltage Above 8 Volt DC Supply : Voltage Above Normal Supply)”
Normal
ECU 8 Volts DC Supply : Voltage Below 8 Volt DC Supply : Voltage Below Normal Supply)”
Normal
Engine Speed Sensor #2 : Abnormal Fre- Secondary Engine Speed Sensor : Abnormal
quency, Pulse Width, or Period Frequency, Pulse Width, or Period
1072–5 791–5 Troubleshooting, “Retarder - Test”

Engine (Compression) Brake Output #1 : Cur- Compression Brake Low/High Solenoid : Cur-
rent Below Normal rent Below Normal
Engine (Compression) Brake Output #1 : Cur- Compression Brake Low/High Solenoid : Cur-
rent Above Normal rent Above Normal
Engine (Compression) Brake Output #2 : Cur- Compression Brake Medium/High Solenoid :
rent Below Normal Current Below Normal
Engine (Compression) Brake Output #2 : Cur- Compression Brake Medium/High Solenoid :
rent Above Normal Current Above Normal
Sensor Supply Voltage 1 : Voltage Above 5 Volt Sensor DC Power Supply : Voltage Supply)”
Normal Above Normal
Sensor Supply Voltage 1 : Voltage Below 5 Volt Sensor DC Power Supply : Voltage Be- Supply)”
Normal low Normal
Auxiliary Pressure #1 : Voltage Above Normal Auxiliary Pressure Sensor : Voltage Above tive) - Test”
Normal
Auxiliary Pressure #1 : Voltage Below Normal Auxiliary Pressure Sensor : Voltage Below tive) - Test”
Normal
544–3
1639–3
Engine Cooling Fan Speed Sensor : Voltage Troubleshooting, “Cooling Fan Speed - Test”
Fan Speed : Voltage Above Normal
Above Normal
1639–8 544–8
Fan Speed : Abnormal Frequency, Pulse Engine Cooling Fan Speed Sensor : Abnormal Troubleshooting, “Cooling Fan Speed - Test”
Width, or Period Frequency, Pulse Width, or Period

Sensor Supply Voltage 1 : Voltage Above 5 Volt Sensor DC Power Supply : Voltage Supply)”
Normal Above Normal
Sensor Supply Voltage 1 : Voltage Below 5 Volt Sensor DC Power Supply : Voltage Be- Supply)”
Normal low Normal
Sensor Supply Voltage 2 : Voltage Above 5 Volt Sensor DC Power Supply #2 : Voltage Supply)”
Normal Above Normal
(continued)
UENR4542-04 33
(Table 7, contd)
Sensor Supply Voltage 2 : Voltage Below 5 Volt Sensor DC Power Supply #2 : Voltage Supply)”
Normal Below Normal
Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Voltage tive) - Test”
Voltage Above Normal Above Normal

Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Voltage Be- tive) - Test”
Voltage Below Normal low Normal

Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Abnormal Supply)”
Abnormal Rate of Change Rate of Change

Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Out of - Test”
Out of Calibration Calibration
Diagnostic Trouble Codes in

Perkins Data Link (PDL) Code
Order
Table 8 lists the diagnostic trouble codes that apply to
the engine. The codes are listed in PDL code order.
Use the electronic service tool to determine the
codes that are active or logged. Then refer to the
appropriate troubleshooting procedure for more
information.
Table 8
List of Diagnostic Trouble Codes
PDL Code and Description J1939 Code and Description Troubleshooting Procedure

Cylinder #1 Injector : Current Below Normal Engine Injector Cylinder #01 : Current Below
Normal
Cylinder #1 Injector : Current Above Normal Engine Injector Cylinder #01 : Current Above
Normal
Normal
Normal
Normal
Normal
Normal
(continued)
34 UENR4542-04
(Table 8, contd)
Normal
Normal
Normal
Normal
Normal
8 Volt DC Supply : Voltage Above Normal ECU 8 Volts DC Supply : Voltage Above Supply)”
Normal
8 Volt DC Supply : Voltage Below Normal ECU 8 Volts DC Supply : Voltage Below Supply)”
Normal
Throttle Position Sensor : Voltage Above Accelerator Pedal Position #1 : Voltage Above
Normal Normal
Throttle Position Sensor : Voltage Below Accelerator Pedal Position #1 : Voltage Below
Normal Normal
Throttle Position Sensor : Abnormal Fre- Accelerator Pedal Position #1 : Abnormal Fre-
quency, Pulse Width, or Period quency, Pulse Width or Period

Fuel Delivery Pressure Sensor : Voltage Engine Fuel Delivery Pressure : Voltage Above tive) - Test”
Above Normal Normal
Fuel Delivery Pressure Sensor : Voltage Below Engine Fuel Delivery Pressure : Voltage Below tive) - Test”
Normal Normal
Fuel Delivery Pressure Sensor : Out of Engine Fuel Delivery Pressure : Out of - Test”
Calibration Calibration
Engine Oil Pressure Sensor : Voltage Above Engine Oil Pressure : Voltage Above Normal tive) - Test”
Normal
Engine Oil Pressure Sensor : Voltage Below Engine Oil Pressure : Voltage Below Normal tive) - Test”
Normal
Engine Oil Pressure Sensor : Abnormal Rate Engine Oil Pressure : Abnormal Rate of Supply)”
of Change Change

Engine Oil Pressure Sensor : Out of Engine Oil Pressure : Out of Calibration - Test”
Calibration
(continued)
UENR4542-04 35
(Table 8, contd)
Engine Coolant Temperature : Voltage Above Engine Coolant Temperature Sensor : Voltage sive) - Test”
Normal Above Normal
Engine Coolant Temperature : Voltage Below Engine Coolant Temperature Sensor : Voltage sive) - Test”
Normal Below Normal
Electrical System Voltage : High Battery Potential / Power Input #1 : High - most Test”
severe (3)

Electrical System Voltage : Low Battery Potential / Power Input #1 : Low - most Test”
severe (3)

Electrical System Voltage : Erratic, Intermit- Battery Potential / Power Input #1 : Erratic, In- Test”
tent, or Incorrect termittent, or Incorrect

Electrical System Voltage : Voltage Above Battery Potential / Power Input #1 : Voltage Test”
Normal Above Normal
Electrical System Voltage : Voltage Below Battery Potential / Power Input #1 : Voltage Test”
Normal Below Normal
Intake Manifold Air Temperature Sensor : Volt- Engine Intake Manifold #1 Temperature : Volt- sive) - Test”
age Above Normal age Above Normal

Intake Manifold Air Temperature Sensor : Volt- Engine Intake Manifold #1 Temperature : Volt- sive) - Test”
age Below Normal age Below Normal

Fuel Temperature Sensor : Voltage Above Engine Fuel Temperature 1 : Voltage Above sive) - Test”
Normal Normal
Fuel Temperature Sensor : Voltage Below Engine Fuel Temperature 1 : Voltage Below sive) - Test”
Normal Normal
Engine Speed Sensor : Abnormal Frequency, Engine Speed : Abnormal Frequency, Pulse
Pulse Width, or Period Width, or Period
247-9 639–9 Troubleshooting, “CAN Data Link - Test”

SAE J1939 Data Link : Abnormal Update Rate J1939 Network #1 : Abnormal Update Rate
253–2 631–2 Troubleshooting, “ECM Software - Install”

Personality Module : Erratic, Intermittent, or Calibration Module : Erratic, Intermittent, or
Incorrect Incorrect
Engine Timing Offset fault Engine Timing Sensor : Other Failure Mode

Engine Timing Calibration : Out of Calibration Engine Timing Sensor : Out of Calibration

5 Volt Sensor DC Power Supply : Voltage Sensor Supply Voltage 1 : Voltage Above Supply)”
Above Normal Normal
5 Volt Sensor DC Power Supply : Voltage Sensor Supply Voltage 1 : Voltage Above Supply)”
Above Normal Normal
(continued)
36 UENR4542-04
(Table 8, contd)
5 Volt Sensor DC Power Supply : Voltage Be- Sensor Supply Voltage 1 : Voltage Below Supply)”
low Normal Normal
5 Volt Sensor DC Power Supply : Voltage Be- Sensor Supply Voltage 1 : Voltage Below Supply)”
low Normal Normal
Atmospheric Pressure Sensor : Voltage Above Barometric Pressure : Voltage Above Normal tive) - Test”
Normal
Atmospheric Pressure Sensor : Voltage Below Barometric Pressure : Voltage Below Normal tive) - Test”
Normal
268-2 630-2 Troubleshooting, “Programmable Parameters”
Programmed Parameter Fault : Erratic, Inter- Calibration Memory : Erratic, Intermittent, or
mittent, or Incorrect Incorrect

Secondary Engine Speed Sensor : Abnormal Engine Speed Sensor #2 : Abnormal Fre-
Frequency, Pulse Width, or Period quency, Pulse Width, or Period
544–3
1639–3
Engine Cooling Fan Speed Sensor : Voltage Troubleshooting, “Cooling Fan Speed - Test”
Fan Speed : Voltage Above Normal
Above Normal
544–8 1639–8
Engine Cooling Fan Speed Sensor : Abnormal Fan Speed : Abnormal Frequency, Pulse Troubleshooting, “Cooling Fan Speed - Test”
Frequency, Pulse Width, or Period Width, or Period

Compression Brake Low/High Solenoid : Cur- Engine (Compression) Brake Output #1 : Cur-
rent Below Normal rent Below Normal
Compression Brake Low/High Solenoid : Cur- Engine (Compression) Brake Output #1 : Cur-
rent Above Normal rent Above Normal
Compression Brake Medium/High Solenoid : Engine (Compression) Brake Output #2 : Cur-
Current Below Normal rent Below Normal
Compression Brake Medium/High Solenoid : Engine (Compression) Brake Output #2 : Cur-
Current Above Normal rent Above Normal
1690–8 - Troubleshooting, “Speed Control - Test”
Throttle #2 Position Sensor : Abnormal Fre-
quency, Pulse Width, or Period

Intake Manifold Pressure Sensor : Voltage Engine Intake Manifold #1 Absolute Pressure : tive) - Test”
Above Normal Voltage Above Normal

Intake Manifold Pressure Sensor : Voltage Be- Engine Intake Manifold #1 Absolute Pressure : tive) - Test”
low Normal Voltage Below Normal

Intake Manifold Pressure Sensor : Abnormal Engine Intake Manifold #1 Absolute Pressure : Supply)”
Rate of Change Abnormal Rate of Change

Intake Manifold Pressure Sensor : Out of Engine Intake Manifold #1 Absolute Pressure : - Test”
Calibration Out of Calibration
(continued)
UENR4542-04 37
(Table 8, contd)
Auxiliary Pressure Sensor : Voltage Above Auxiliary Pressure #1 : Voltage Above Normal tive) - Test”
Normal
Auxiliary Pressure Sensor : Voltage Below Auxiliary Pressure #1 : Voltage Below Normal tive) - Test”
Normal
Auxiliary Temperature Sensor : Voltage Above Auxiliary Temperature #1 : Voltage Above sive) - Test”
Normal Normal
Auxiliary Temperature Sensor : Voltage Below Auxiliary Temperature #1 : Voltage Below sive) - Test”
Normal Normal
5 Volt Sensor DC Power Supply #2 : Voltage Sensor Supply Voltage 2 : Voltage Above Supply)”
Above Normal Normal
5 Volt Sensor DC Power Supply #2 : Voltage Sensor Supply Voltage 2 : Voltage Below Supply)”
Below Normal Normal
Ether Injection Control Solenoid : Current Be- Engine Start Enable Device 1 : Current Below
low Normal Normal
Ether Injection Control Solenoid : Current Engine Start Enable Device 1 : Current Above
Above Normal Normal
38 UENR4542-04
Event Codes
Event Codes
i06981548
Event Codes
Event codes are generated when abnormal operating

conditions exist. A further explanation of event codes
and the engine monitoring system are described after
Table 10 .
Event Codes in J1939 Code Order

Table 9 is a list of the event codes for the engine. The
event codes are listed in order of J1939 codes. The
event codes are cross-referenced with the
appropriate procedure that can be used to
troubleshoot the code.
Table 9
Event Codes
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
- E662 (1) Troubleshooting, “Cooling Fan Speed - Test”

High Engine Cooling Fan Speed
- E662 (3) Troubleshooting, “Cooling Fan Speed - Test”

94-0 E96 (3) Troubleshooting, “Fuel Pressure Is High”

Engine Fuel Delivery Pressure : High - most High Fuel Pressure
severe (3)
94-1 E198 (3) Troubleshooting, “Fuel Pressure Is Low”

Engine Fuel Delivery Pressure : Low - most Low Fuel Pressure
severe (3)
94-15 E96 (1) Troubleshooting, “Fuel Pressure Is High”

Engine Fuel Delivery Pressure : High - least High Fuel Pressure
severe (1)

Engine Fuel Delivery Pressure : Low - least se- Low Fuel Pressure
vere (1)

Engine Fuel Delivery Pressure : Low - moder- Low Fuel Pressure
ate severity (2)
100-1 E360 (3) Troubleshooting, “Oil Pressure Is Low”

Engine Oil Pressure : Low - most severe (3) Low Engine Oil Pressure

Engine Oil Pressure : Low - least severe (1) Low Engine Oil Pressure

Engine Oil Pressure : Low - moderate severity Low Engine Oil Pressure
(2)
(continued)
UENR4542-04 39
Event Codes
(Table 9, contd)
102–15 E162 (1) Troubleshooting, “Boost Pressure Is High”
Engine Intake Manifold #1 Pressure : High - High Boost Pressure
least severe
102–16 E162 (2) Troubleshooting, “Boost Pressure Is High”
Engine Intake Manifold #1 Pressure : High - High Boost Pressure
moderate severity
105-0 E539 (3) Troubleshooting, “Intake Manifold Air Temper-

Engine Intake Manifold #1 Temperature : High High Intake Manifold Air Temperature ature Is High”
- most severe (3)

- least severe (1)

- moderate severity (2)
110-0 E361 (3) Troubleshooting, “Coolant Temperature Is

Engine Coolant Temperature : High - most se- High Engine Coolant Temperature High”
vere (3)

Engine Coolant Temperature : High - least se- High Engine Coolant Temperature High”
vere (1)

Engine Coolant Temperature : High - moderate High Engine Coolant Temperature High”
severity (2)
111-0 E2143 (3) Troubleshooting, “Coolant Level Is Low”

Engine Coolant Level : Low - most severe (3) Low Engine Coolant Level

Engine Coolant Level : Low - least severe (1) Low Engine Coolant Level

Engine Coolant Level : Low - moderate se- Low Engine Coolant Level
verity (2)
173-16 E194 (2) Troubleshooting, “Exhaust Temperature Is

Engine Exhaust Gas Temperature : High - High Exhaust Temperature High”
moderate severity (2)
174-0 E363 (3) Troubleshooting, “Fuel Temperature Is High”

Engine Fuel Temperature 1 : High - most se- High Fuel Supply Temperature
vere (3)

Engine Fuel Temperature 1 : High - least se- High Fuel Supply Temperature
vere (1)

Engine Fuel Temperature 1 : High - moderate Fuel Temperature Is High
severity (2)
190-0 E362 (3) Troubleshooting, “Engine Overspeeds”

Engine Speed : High - most severe (3) Engine Overspeed
190-15 E362 (1) Troubleshooting, “Engine Overspeeds”

Engine Speed : High - least severe (1) Engine Overspeed
190–16 E362 (2) Troubleshooting, “Engine Overspeeds”

Engine Speed : High - moderate severity (2) Engine Overspeed
(continued)
40 UENR4542-04
Event Codes
(Table 9, contd)
441–0 E445 (3) Troubleshooting, “Symptom troubleshooting”
Auxiliary Temperature #1 : High - most severe High Auxiliary Temperature The troubleshooting procedure will depend on
(3) the symptom.

Auxiliary Temperature #1 : High - least severe High Auxiliary Temperature The troubleshooting procedure will depend on
(1) the symptom.
441-16 E445 (2) Troubleshooting, “Symptom troubleshooting”

Auxiliary Temperature #1 : High - moderate se- High Auxiliary Temperature The troubleshooting procedure will depend on
verity (2) the symptom.
1237–31 E85 (1) The engine shutdown override switch is used

Engine Shutdown Override Switch Engine Shutdown Overridden to keep the engine running when the ECM is
commanding that the engine be stopped. This
code indicates that the operator chose to keep
the engine running in conditions that typically
can damage the engine.

Auxiliary Pressure #1 : High - most severe (3) High Auxiliary Pressure The troubleshooting procedure will depend on
the symptom.

Auxiliary Pressure #1 : High - least severe (1) High Auxiliary Pressure The troubleshooting procedure will depend on
the symptom.

Auxiliary Pressure #1 : High - moderate se- High Auxiliary Pressure The troubleshooting procedure will depend on
Event Codes in Perkins Data Link

(PDL) Code Order
Table 10 is a list of the event codes for the engine.
The event codes are listed in order of PDL codes.
The event codes are cross-referenced with the
appropriate procedure that can be used to
troubleshoot the code.
Table 10
Event Codes
PDL Code and Description J1939 Code and Description Troubleshooting Procedure
E85 (1) 1237–31 The engine shutdown override switch is used

Engine Shutdown Overridden Engine Shutdown Override Switch to keep the engine running when the ECM is
commanding that the engine be stopped. This
code indicates that the operator chose to keep
the engine running in conditions that typically
can damage the engine.
E96 (1) 94-15 Troubleshooting, “Fuel Pressure Is High”

High Fuel Pressure Engine Fuel Delivery Pressure : High - least
severe (1)
E96 (3) 94-0 Troubleshooting, “Fuel Pressure Is High”

High Fuel Pressure Engine Fuel Delivery Pressure : High - most
severe (3)
E162 (1) 102–15 Troubleshooting, “Boost Pressure Is High”

High Boost Pressure Engine Intake Manifold #1 Pressure : High -
least severe
(continued)
UENR4542-04 41
Event Codes
(Table 10, contd)

E162 (2) 102–16 Troubleshooting, “Boost Pressure Is High”
High Boost Pressure Engine Intake Manifold #1 Pressure : High -
moderate severity
E194 (2) 173-16 Troubleshooting, “Exhaust Temperature Is

High Exhaust Temperature Engine Exhaust Gas Temperature : High - High”
E198 (1) 94-17 Troubleshooting, “Fuel Pressure Is Low”

Low Fuel Pressure Engine Fuel Delivery Pressure : Low - least se-
vere (1)

Low Fuel Pressure Engine Fuel Delivery Pressure : Low - moder-
ate severity (2)

Low Fuel Pressure Engine Fuel Delivery Pressure : Low - most
severe (3)
E255 (1) - The ECM detected the activation of the diag-

Diagnostic Reset nostic reset switch. Logged event codes and
logged diagnostic codes will be deleted. Any
latched condition such as engine derates or
engine shutdowns will be reset. Determine the
reason the switch has been activated. Use the
electronic service tool to check for active diag-
nostic codes or event codes. Resolve any is-
sues that are present. Return the engine to
service.
E360 (1) 100-17 Troubleshooting, “Oil Pressure Is Low”
Low Engine Oil Pressure Engine Oil Pressure : Low - least severe (1)

Low Engine Oil Pressure Engine Oil Pressure : Low - moderate severity
(2)

Low Engine Oil Pressure Engine Oil Pressure : Low - most severe (3)
E361 (1) 110-15 Troubleshooting, “Coolant Temperature Is

High Engine Coolant Temperature Engine Coolant Temperature : High - least se- High”
vere (1)

High Engine Coolant Temperature Engine Coolant Temperature : High - moderate High”
severity (2)

High Engine Coolant Temperature Engine Coolant Temperature : High - most se- High”
vere (3)
E362 (1) 190-15 Troubleshooting, “Engine Overspeeds”

Engine Overspeed Engine Speed : High - least severe (1)
E362 (2) 190–16 Troubleshooting, “Engine Overspeeds”

Engine Overspeed Engine Speed : High - moderate severity (2)
E362 (3) 190-0 Troubleshooting, “Engine Overspeeds”

Engine Overspeed Engine Speed : High - most severe (3)
E363 (1) 174-15 Troubleshooting, “Fuel Temperature Is High”

High Fuel Supply Temperature Engine Fuel Temperature 1 : High - least se-
vere (1)
(continued)
42 UENR4542-04
Event Codes
(Table 10, contd)

High Fuel Supply Temperature Engine Fuel Temperature 1 : High - moderate
severity (2)

High Fuel Supply Temperature Engine Fuel Temperature 1 : High - most se-
vere (3)
E368 (1) - Troubleshooting, “Inlet Air Temperature Is

High Inlet Air Temperature High”
E368 (2) - Troubleshooting, “Inlet Air Temperature Is

High Inlet Air Temperature High”
E443 (1) 1387–15 Troubleshooting, “Symptom troubleshooting”

High Auxiliary Pressure Auxiliary Pressure #1 : High - least severe (1) The troubleshooting procedure will depend on
the symptom.

High Auxiliary Pressure Auxiliary Pressure #1 : High - moderate se- The troubleshooting procedure will depend on

High Auxiliary Pressure Auxiliary Pressure #1 : High - most severe (3) The troubleshooting procedure will depend on
the symptom.

High Auxiliary Temperature Auxiliary Temperature #1 : High - least severe The troubleshooting procedure will depend on
(1) the symptom.

High Auxiliary Temperature Auxiliary Temperature #1 : High - moderate se- The troubleshooting procedure will depend on

High Auxiliary Temperature Auxiliary Temperature #1 : High - most severe The troubleshooting procedure will depend on
(3) the symptom.
E539 (1) 105-15 Troubleshooting, “Intake Manifold Air Temper-

High Intake Manifold Air Temperature Engine Intake Manifold #1 Temperature : High ature Is High”
- least severe (1)

- moderate severity (2)

- most severe (3)
E662 (1) - Troubleshooting, “Cooling Fan Speed - Test”

E662 (3) - Troubleshooting, “Cooling Fan Speed - Test”

E2143 (1) 111-17 Troubleshooting, “Coolant Level Is Low”

Low Engine Coolant Level Engine Coolant Level : Low - least severe (1)

Low Engine Coolant Level Engine Coolant Level : Low - moderate se-
verity (2)

Low Engine Coolant Level Engine Coolant Level : Low - most severe (3)
Parts of the Event Code event code. The fourth “(X)” assigns one of three
levels to the active event code according to the
Event Code – “E” identifies the code as an event severity of the abnormal system condition. Next is a
code. “XXX(X)” represents a numeric identifier for the
UENR4542-04 43
Event Codes
code description. Refer to the following example:
• E360(1) Low Oil Pressure

The definition for the levels of severity for an event
are defined below:
Level 1 – Level 1 alerts the operator that an engine
system requires attention. The operator should check
that the involved system condition or the operator
should perform maintenance on the involved system
at the earliest possible time.
Level 2 – Level 2 requires a change in the operation
of the engine or the performance of a maintenance
procedure. Failure to correct the problem that caused
this warning may result in damaged the engine
components.
Level 3 – Level 3 requires an immediate safe
shutdown of the engine to avoid damage to the
engine or injury to personnel around the engine. The
problem that caused the event must be corrected
before engine operation can resume.
Active Event Codes

An active event code represents a problem with
engine operation. Correct the problem as soon as
possible.
Active event codes are listed in ascending numerical
order. The code with the lowest number is listed first.
Illustration 22 is an example of the operating range of Example of the typical operating range of a sensor
a sensor.
(1) This area represents the normal operating range of the engine
parameter.
(2) In these areas, the engine is operating in an unsafe operating
range of the monitored parameter. An event code will be
generated for the monitored parameter. The sensor circuit
does not have an electronic problem.
(3) In these areas, the signal from the sensor is outside of the
operating range of the sensor. The sensor circuit has an
electronic problem. A diagnostic code will be generated for the
sensor circuit. Refer to Troubleshooting, “Diagnostic Trouble
Codes” for additional information on diagnostic codes.
Logged Event Codes

When the Electronic Control Module (ECM)
generates an event code, the ECM logs the code in
permanent memory. The ECM has an internal
diagnostic clock. The ECM will record the following
information when an event code is generated:
• The hour of the first occurrence of the code

• The hour of the last occurrence of the code
• The number of occurrences of the code

Logged events are listed in chronological order. The
most recent event code is listed first.
44 UENR4542-04
Event Codes
This information can be helpful for troubleshooting Be sure to check the connectors. This step is
intermittent problems. Logged codes can also be important for problems that are intermittent. Refer to
used to review the performance of the engine. Troubleshooting, “Electrical Connectors - Inspect”.
Clearing Event Codes If these steps do not resolve the problem, refer to
Table 10 or Table 9 for the procedure to troubleshoot
A code is cleared from memory when one of the the event code.
following conditions occur:
• The code does not recur for 100 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
• The service technician manually clears the code.

Always clear logged event codes after investigating
and correcting the problem which generated the
code.
Troubleshooting
For the basic troubleshooting of the engine, perform
the following steps to diagnose a malfunction:
1. Obtain the following information about the
complaint:
• The event and the time of the event
• Determine the conditions for the event. The

conditions will include the engine rpm and the
load.
• Determine if there are any systems that were

installed by the dealer or by the customer that
could cause the event.
• Determine whether any additional events

occurred.
2. Verify that the complaint is not due to normal

engine operation. Verify that the complaint is not
due to error of the operator.
3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
history of the engine.
4. Perform a visual inspection. Inspect the following
items:
• Fuel supply
• Oil level
• Oil supply
• Wiring
• Connectors
UENR4542-04 45
Symptom Troubleshooting
Symptom Troubleshooting Follow the Procedures

If these inspections do not reveal any problems, use
the procedure that best describes the symptoms. The
procedures in this manual provide the most efficient
way to determine the root cause of the problem.
i05958963
i06701836
Acceleration Is Poor or
Use the following guidelines as you troubleshoot an Throttle Response Is Poor
engine symptom:
Gather Information Probable Causes

Interview the operator about the problem before you
begin troubleshooting, when possible. • Codes
Verify the Problem • Parameters

Attempt to duplicate the problem. Try to duplicate the • Throttle Signal
operating conditions, when possible. Verify that the
complaint is not due to normal engine operation. • Air Inlet and Exhaust System
Diagnostic Codes • Fuel System

Check for any logged diagnostic codes. • Engine Load
• Determine if the logged diagnostic codes correlate • Valve Lash
to probable causes.
• Determine if the logged diagnostic codes occur at Recommended Actions
the same time as the symptoms. Note: The procedures have been listed in order of
• Determine if the logged diagnostic codes are probability. Complete the procedures in order.
logged repeatedly. Note: If the problem only occurs under certain
Repair all active diagnostic codes. Refer to conditions, test the engine under those conditions.
Troubleshooting, “Diagnostic Trouble Codes” for the Examples of certain conditions are high engine
correct troubleshooting procedure. speed, full load, and engine operating temperature.
Troubleshooting the symptoms under other
Connectors and Wiring conditions can give misleading results.
Check the wiring and the connectors for the following
problems:
• Damage
• Abrasion
• Corrosion
• Incorrect attachment
46 UENR4542-04
Table 11
Troubleshooting Test Steps Values Results
1. Check for Codes Result: A diagnostic code is present.

Diagnostic
A. Connect the electronic service tool to the service tool Codes Repair: Troubleshoot the code.
connector.
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Incorrect Parameters Result: The parameters are correct.

Parameters
A. Use the electronic service tool to verify that the correct param- Proceed to Test Step 3.
eters are being used. Refer to Troubleshooting, “Configuration
Parameters” for additional information. Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Trouble-

shooting, “Configuration Parameters” for additional
information.
3. Throttle Signal Result: The throttle signal is stable.

Throttle Signal Proceed to Test Step 4.
A. Monitor the status for “Throttle Position” on the electronic serv-
ice tool. Verify that the status for “Throttle Position” is stable and Result: The throttle signal is not stable.
that the engine is able to reach high idle speed.
Repair: Make the necessary repairs, Refer to the appro-
priate circuit test.
4. Restriction in the Air Inlet and Exhaust System Result: There are no restrictions in the air inlet or exhaust
Restrictions system.
A. Observe the check engine lamp. Check for an air filter restric-
tion indicator. Replace any plugged air filters. Refer to the Opera- Proceed to Test Step 5.
tion and Maintenance Manual.
Result: There are restrictions in the air inlet or exhaust
B. Check the air inlet and exhaust system for restrictions and/or system.
leaks.
Repair: Make the necessary repairs, Refer to Systems
Operation, Testing and Adjusting, “Air Inlet and Exhaust
System - Inspect” for additional information.
(continued)
UENR4542-04 47
(Table 11, contd)

5. Check the Fuel System Result: The fuel pressure is OK.
Fuel system
Refer to Systems Operation, Testing and Adjusting, “Fuel System” Proceed to Test Step 6.
for additional information.
Result: The fuel pressure is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the
fuel gauge only. Repair: Replace the fuel filters. Clean the primary filter/
water separator of debris. Refer to the Operation and
B. Ensure that the vent in the fuel cap is not filled with debris. Maintenance Manual for details.
C. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position.
D. Inspect the fuel system. Refer to Systems Operation/Testing

and Adjusting, “Fuel System - Inspect” for additional information.
E. Cold weather adversely affects the characteristics of the fuel.

Refer to the engines Operation and Maintenance Manual for infor-
mation on improving the characteristics of the fuel during cold-
weather operation. Cold mode (if applicable) is activated when-
ever the engine coolant temperature falls below a predetermined
value. Monitor the status screen on the electronic service tool to
verify that the engine has exited cold mode. Observe the reading
for coolant temperature on the electronic service tool.
Refer to "Cold Mode Operation" within the Systems Operation,

“General Information”.
F. Check fuel quality. Refer to Systems Operation/Testing and Ad-

justing, “Fuel Quality - Test” for the proper procedure. Check the
fuel tank for debris or foreign objects which may block the fuel
supply.
G. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation, Testing and Adjusting, “Fuel System” for
test information.
6. Engine Load Engine loads Result: There is not a parasitic load.
A. Check accessories and parasitic loads on the engine. Proceed to Test Step 7.
Result: There is a parasitic load.
Repair: Remove the parasitic load.
7. Valve Lash Valve lash Result: The valve lash is not set correctly.
A. Check the valve lash. The valve lash can affect the perform- Repair: Set the valve lash. Refer to Systems Operation,
ance of the engine. Testing and Adjusting, “Engine Valve Lash - Inspect/Ad-
just” for the correct procedure.
STOP
i06244264 • Charging Circuit
Alternator Problem Recommended Actions

Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Probable Causes
• Alternator
48 UENR4542-04
Table 12
1. Condition of the Alternator Drive Belts Drive belt Result: The alternator drive belts are in good condition
and the belt tension is correct.
A. Inspect the condition of the alternator drive belts.
B. Check the belt tension. If the engine is equipped with an
automatic belt tensioner, check the automatic belt tensioner. Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
Repair: If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and Assembly for
the correct procedure.
If necessary, replace the automatic belt tensioner. Refer to

Disassembly and Assembly for the correct procedure.
2. Condition of the Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Repair: Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.
Repair: Tighten the nut.
Result: There is not excessive wear on the alternator drive

pulley.
3. Wear of the Alternator Bearings Alternator bearings Result: The alternator bearings are OK.
A. Check the alternator bearings for signs of wear. Proceed to Test Step 4.
Result: The alternator bearings are not OK.
Repair: Repair the alternator or replace the alternator, as

needed. Refer to Disassembly and Assembly for the cor-
rect procedure.
4. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating
alternator properly.
A. Verify that the alternator or the regulator is operating cor-
rectly. Refer to Systems Operation, Testing and Adjusting, Proceed to Test Step 5.
“Charging System - Test” for the proper testing procedures.
Result: The regulator and alternator are not operating
properly.
Repair: Repair the alternator and regulator or replace the

alternator and regulator, as needed. Refer to Disassembly
and Assembly for the correct procedure.
5. Inspection of the Charging Circuit Charging circuit Result: The charging circuit is not working properly.
A. Inspect the battery cables, wiring, and connections in the Repair: Clean all connections and tighten all connections.
charging circuit. Replace any faulty parts.
UENR4542-04 49
If the procedure did not correct the issue, contact the

Dealer Solutions Network (DSN).
i05959017
Battery Problem
Probable Causes
• Battery
• Switched Battery Circuit
Recommended Actions
Download the Product Status Report from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Troubleshoot any
active codes before continuing with this procedure.
Table 13
1.Check the Battery Battery Result: The battery is OK.
A. Verify that the battery is no longer able to hold a charge. Refer Proceed to Test Step 2.
to Systems Operation/Testing and Adjusting, “Battery - Test”.
Result: The battery is not OK.
Repair: Replace the battery. Refer to Disassembly and As-

sembly for the correct procedure.
2. Check the Switched Battery Circuit Switched Result: The switched battery circuit drained the battery by
battery being left in the ON position.
A. Verify that a switched battery circuit drained the battery by circuit
being left in the ON position. Repair: Charge the battery. Verify that the battery is able to
maintain a charge. Refer to Systems Operation/Testing and
Adjusting for the correct procedure.
i06628604
Boost Pressure Is High
Use this procedure to troubleshoot a high boost

pressure or use this procedure if one of the following
event codes is active. Access the monitoring system
on the electronic service tool to view the current trip
points for these codes.
50 UENR4542-04
Table 14
Code Description
J1939 Code PDL Code (code descriptions may vary) Comments
102–15 E162(1) High Boost Pressure The boost pressure is above the trip point for
high boost pressure.
The code is logged.
102–16 E162(2) High Boost Pressure The boost pressure is above the trip point for
high boost pressure.
The code is logged. The engine power will be
derated.
Probable Causes
• Excessive engine load
Recommended Actions
Excessive Engine Load
Reduce the load on the engine.
i06245217
Coolant Contains Fuel
Probable Causes
• Leaking injector sleeve and/or damaged seal
UENR4542-04 51
Recommended Actions
Table 15
1. Leaking injector sleeve and/or damaged seal Result: The injector sleeve is leaking.
Injector sleeve
A. Remove the valve mechanism covers. Repair: Remove the injector sleeve that is leaking. Carefully
inspect the sleeve for damage. If there are visible signs of
B. Remove the fuel injectors from the cylinder head. damage to the injector sleeve, replace the sleeve. Replace the
O-ring seals for the injector sleeve and reinstall the sleeve. Re-
Refer to the Disassembly and Assembly manual for details. place any damaged components.
Do not allow the pressure on the cooling system to exceed Coolant may also be contaminating the fuel system. After the
103 kPa (15 psi) during the test. Damage to the cooling engine is shut down, the retention of pressure in the cooling
system may result from applying excessive pressure. system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of
C. Pressurize the cooling system in order to identify the injector coolant in the fuel system may damage injectors and other fuel
sleeve that is leaking. Closely inspect the sealing joint around system components. Ensure that all of the fuel system compo-
the top of the injector sleeve. Small amounts of coolant will be nents are in good repair prior to returning the engine to
dripping from the injector sleeve that is leaking. service.
Coolant may also be contaminating the fuel system. After the Do not crank the engine if a cylinder is full of fluid. Cata-
engine is shut down, the retention of pressure in the cooling strophic damage can occur to the engine.
system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of Evacuate all cylinders of fluid before trying to start the engine.
coolant in the fuel system may damage injectors and other fuel
system components. Ensure that all of the fuel system compo-
nents are in good repair prior to returning the engine to service.
Complete the procedure in the order in which the

steps are listed.
i06245230
Coolant Contains Oil
Probable Causes
• Engine Oil Cooler
• Power Train Oil Cooler (if equipped)

• Water-Cooled Turbocharger
• Cylinder Head Gasket

• Block
The procedures have been listed in order of
Verify the presence of oil in the coolant with a
scheduled oil sample. Verification must be made
before performing the procedure.
52 UENR4542-04
Recommended Actions
Table 16
1. Leak in the Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.
A. Check for leaks in the engine oil cooler. Refer to Testing Repair: Install a new oil cooler core. Refer to the Disas-
and Adjusting for the proper procedure. sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.
Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the crankcase with the proper oil after
the leak has been repaired. Refer to the Operation and
Maintenance Manual for the correct oil capacities and
viscosity.
Result: A leak was not found in the engine oil cooler.
2. Leak in the Power Train Oil Cooler Power train cooler Result: A leak is found in the power train oil cooler.
A. Check for leaks in the power train oil cooler. Refer to Test- Repair: Install a new oil cooler core. Refer to the Disas-
ing and Adjusting for the proper procedure sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the crankcase. Refill the oil after the leak has been re-
paired. Refer to the Operation and Maintenance Manual
for the correct oil capacities and viscosity.
Result: A leak was not found in the power train oil cooler.
(continued)
UENR4542-04 53
(Table 16, contd)

3. Water-Cooled Turbocharger (if equipped) Turbocharger Result: The turbocharger is cracked.
A. Inspect the turbocharger for cracks. Repair: Replace the turbocharger. Refer to the engine
B. Remove the oil drain line from the turbo and pressurize the
cooling system, Refer to Testing and Adjusting, “Cooling Sys- Flush the cooling system, Refer to the Operation and
tem - Test”. Maintenance Manual for the correct procedure.
C. Check the turbocharger for coolant leakage. Refill the cooling system with the proper coolant. Refer to
the oil. Refill the oil after the leak has been repaired. Refer
to the Operation and Maintenance Manual for the correct
oil capacities.
Result: The turbocharger is not cracked.
4. Cylinder Head Gasket Cylinder head Result: New cylinder head gasket and water seals were
gasket installed.
A. Remove the cylinder head. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 5.
B. Check the cylinder liner projection. Refer to the Systems

Operation/Testing and Adjusting manual.
C. Install a new cylinder head gasket and new water seals in

the spacer plate. Refer to the Disassembly and Assembly
manual.
5. Cylinder Head Cylinder head Result: A crack is found in the cylinder head.
A. Check for cracks in the cylinder head. Perform a leak test Repair: Repair the cylinder head and/or replace the cylin-
on the cylinder head. Refer to System Operation, Testing and der head. Refer to the Disassembly and Assembly
Adjusting for the proper procedure for checking the cylinder manual.
head.
Result: A crack is not found in the cylinder head.
Result: A crack is found in the cylinder block.

6. Cylinder Block Cylinder block
Repair: Repair the cylinder block or replace the cylinder
A. Inspect the cylinder block for cracks. block. Inspect the top deck. Refer to Systems Operation,
Testing and Adjusting, “Cylinder Block - Inspect” for the
proper inspection procedure.
54 UENR4542-04

steps are listed.
i06300672
Coolant Level Is Low
Use this procedure in order to troubleshoot low

coolant level or use this procedure if one of the
following codes is active. Refer to Troubleshooting,
“Diagnostic Trouble Codes” for information about
diagnostic codes. Access the monitoring system on
the electronic service tool in order to view the current
trip points for these codes. For information on the
engine monitoring system, refer to Troubleshooting,
“Diagnostic Capabilities”.
Note: Some of the following codes may not be

applicable for certain applications.
Table 17
J1939 Code PDL Code Code Description System Response

The engine has been running for 60 seconds. The engine cool-
Engine Coolant Level : Low - Most ant level has fallen below the coolant level sensor for the
111-1 E2143 (3)
Severe (3) specified delay time.
Engine power is derated. The code is logged.
Engine Coolant Level : Low - Least ant level has fallen below the coolant level sensor for the
111-17 E2143 (1)
Severe (1) specified delay time.
The code is logged.
Engine Coolant Level : Low - Moder- ant level has fallen below the coolant level sensor for the
111-18 E2143 (2)
ately Severe (2) specified delay time.
Engine power is derated. The code is logged.
Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant level sensor
Recommended Actions
UENR4542-04 55
Table 18
1. Low Coolant Level and/or Coolant Leakage Coolant level Result: The engine coolant level is OK.
A. Inspect the coolant level. Proceed to Test Step 2.
Result: The engine coolant level is not OK.
Repair: Troubleshoot the cause of the incorrect coolant

level.
1. Check for the correct mixture of antifreeze and water. Re-

fer to Operation and Maintenance Manual.
2. Check the cooling system for leaks. Refer to Systems Op-

eration/Testing and Adjusting, “Cooling System - Test” for
the correct procedure. Repair any leaks immediately.
3. Check for air in the cooling system. Refer to Systems Op-

eration/Testing and Adjusting, “Testing the Cooling System”
for the correct procedure.
2. Faulty Sensor Coolant level Result: The coolant level sensor is not operating properly.
sensor
A. If an electrical problem with the coolant level sensor is sus- Repair: Replace the coolant level sensor.
pected, refer to Troubleshooting, “Coolant Level - Test” for informa-
tion that is related to troubleshooting an electrical problem with the
coolant level sensor.

steps are listed.
i06300696
Coolant Temperature Is High
Use this procedure in order to troubleshoot high

coolant temperature or use this procedure if one of
the following event codes is active. Access the
monitoring system on the electronic service tool in
order to view the current trip points for these codes.
Table 19
J1939 Code PDL Code Code Description Comments

The engine coolant temperature has exceeded the
Engine Coolant Temperature High trip point and the delay time has expired.
110-0 E361 (3)
- Most Severe (3) Engine power is derated.
The code is logged.

Engine Coolant Temperature
110-15 E361 (1) trip point and delay time has expired.
High- Least Severe (1)
The code is logged.

High Engine Coolant Temperature
110-16 E361 (2) trip point and the delay time has expired.
High - Moderate Severity (2)
The code is logged.
56 UENR4542-04
Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant Temperature Sensor
• Water Temperature Regulator and/or Pressure

Relief Valve
• Radiator
• Heat Exchanger
• Engine Cooling Fan (if equipped)
• Coolant Pump
• Cylinder Head Gasket
Recommended Actions
Table 20
1. Coolant Engine coolant Result: The engine coolant level is OK.

level
A. Inspect the coolant level. Proceed to Test Step 2.
Result: The engine coolant level is not OK.
Repair: Check the cooling system for leaks. Refer to Trou-

bleshooting, “Coolant Level is Low” for additional informa-
tion. Repair any leaks immediately.
2. Coolant Temperature Sensor and/or the Circuit Coolant tem- Result: The temperature sensor is working properly.
perature
A. Check the reading of the coolant temperature on the electronic sensor Proceed to Test Step 3.
service tool. The temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable. Result: The temperature sensor is not working properly.
Repair: Troubleshoot the circuit and the coolant tempera-

ture sensor. Refer to Troubleshooting, “Sensor Signal
(Analog, Passive) - Test”.
3. Water Temperature Regulator and/or Pressure Relief Valve Temperature Result: The pressure relief valve and/or the water temper-
regulator ature regulator are operating properly.
A. Pressure-test the cooling system. Refer to Systems Operation/
Testing and Adjusting for the correct procedure. Proceed to Test Step 4.
B. Check that the seating surfaces of the pressure relief valve and Result: The pressure relief valve and/or the water temper-
the radiator cap are clean and undamaged. ature regulator are not operating properly.
C. Check operation of the pressure relief valve and/or the water Repair: Clean the components and/or replace the
temperature regulator. components.
(continued)
UENR4542-04 57
(Table 20, contd)

4. Radiator Radiator Result : The radiator fins are not damaged and the radia-
tor does not have an internal blockage.
A. Check the radiator fins for dirt, debris, and/or damage.
B. Check for collapsed hoses and/or other restrictions.
Result : The radiator fins are damaged.
C. Check the radiator for internal blockage.
Repair: Remove any dirt and/or debris and straighten any
Ensure that the radiator size is sufficient. An undersized radiator bent fins.
does not have enough area for the effective release of heat. An un-
dersized radiator may cause the engine to run at a temperature Result : The radiator has internal blockage.
that is higher than normal. The normal temperature is dependent
on the ambient temperature. Remove the blockage.
5. Heat Exchanger Heat Result : The flow of cooling water is sufficient.

exchanger
A. Check for sufficient flow and temperature of the cooling water Proceed to Test Step 6.
through the heat exchanger.
Result : The flow of cooling water is not sufficient.
Repair: Determine the location of the obstruction. If the

temperature of the cooling water is too high, determine the
cause. Ensure that the size of the heat exchanger is suffi-
cient. Make the necessary repairs.
6. Faulty Engine Cooling Fan (if equipped) Fan belt or Result : The fan belt is tensioned correctly.
clutch
A. If the fan is belt driven, check for loose drive belts. Proceed to Test Step 7.
A loose fan drive belt will cause a reduction in the air flow across Result : The fan belt is not tensioned correctly.
the radiator.
Repair: Adjust the tension of the fan drive belt, if neces-
B. Check the fan clutch, if equipped. sary. Refer to Operation and Maintenance Manual.
A fan clutch or a hydraulic driven fan that is not turning at the cor- Result : The fan clutch is operating correctly.
rect speed can cause improper air speed across the radiator core.
The lack of proper air flow across the radiator core can cause the Proceed to Test Step 7.
coolant not to cool to the proper temperature differential.
Result : The fan clutch is not operating correctly.
Repair: Refer to Troubleshooting, “Cooling Fan Control -

Test” for troubleshooting information.
(continued)
58 UENR4542-04
(Table 20, contd)

7. Inspection of the Coolant Pump Coolant pump Result : The coolant pump is operating correctly.
A. Inspect the impeller of the coolant pump for damage and/or Proceed to Test Step 8.
erosion.
Result : The coolant pump is not operating correctly.
B. Make sure that the drive gear is not loose on the drive shaft of
the coolant pump. Repair: If necessary, replace the coolant pump. Refer to
9. Cylinder Head Gasket Head gasket Result : The cylinder head was checked for leaks and the
gasket was replaced.
A. Remove the cylinder head. Refer to the Disassembly and As-
sembly manual. Verify that the problem was corrected.
B. Check the cylinder liner projection. Refer to the Systems Opera-

tion/Testing and Adjusting manual.
C. Pressure test the head for leaks.
D. Install a new cylinder head gasket and new water seals in the
spacer plate. Refer to the Disassembly and Assembly manual.

steps are listed.
i06245465
Cylinder Is Noisy
Probable Causes
• Active codes and logged codes
• Low quality fuel
• Injectors
• Lack of lubrication
• Valve train components

• Gear train and components of the lower end
Recommended Actions
UENR4542-04 59
Table 21
1. Active Codes and Logged Codes Codes Result: A diagnostic trouble code is not active or logged.
A. Establish communication between the electronic service tool Proceed to Test Step 2.
and the Electronic Control Module (ECM).
Result: A diagnostic trouble code is active or logged.
Repair: Troubleshoot the active or logged codes.
2. Low Quality Fuel Fuel Result: The fuel quality is OK.
A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 3.
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is Result: The fuel quality is not OK.
being used for the engine. Refer to Systems Operation/Testing and
Adjusting, “Fuel System Quality Test” for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.
3. Injectors Injector Sole- Result: The test was successful.

noid Test or
Cylinder Cut- Proceed to Test Step 4.
A. Perform the “Injector Solenoid Test” on the electronic service out Test
tool in order to determine if all of the injector solenoids are being Result: The test was not successful.
energized by the ECM.
Repair: Diagnose the problem and then repair the
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” problem.
under the “Diagnostics” menu.
Reset all active codes and clear all logged codes.
C. Perform the “Automatic Cylinder Cutout Test” on the electronic
service tool. Verify that the repair eliminated the problem.
4. Lack of Lubrication Lubrication Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Proceed to Test Step 5.
arms.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean. not have proper lubrication.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
(continued)
60 UENR4542-04
(Table 21, contd)

5. Valve Train Components Valve train Result: The valve train components are not damaged.
A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Proceed to Test Step 6.
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the valve
cover from the suspect cylinders. Check the following items for Repair: Make the necessary repairs, Verify that the repair
damage: eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
4. Camshaft followers
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
Refer to Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
6. Gear Train and Components of the Lower End Gear train Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.
Complete the procedure in the order in which the Recommended Actions

steps are listed.
i05962229 probability. Complete the procedures in the order of
the listed test steps.
ECM Does Not Communicate
with Other Modules
Probable Causes
• Wiring and/or electrical connectors
• Perkins Data Link
• CAN data link (if equipped)

• Electronic Control Module (ECM)
UENR4542-04 61
Table 22
1. Check for correct installation of the con- ECM Result: Connectors are installed incorrectly.
nectors for the ECM J1/P1, J2/P2, and J3/
P3. Repair: Correct the installation issue. Return
Refer to Troubleshooting, “Electrical Connec- to service.
tors - Inspect”
Result: Connectors are installed correctly.
Proceed to Test Step 2
Result: The electronic service tool will not

2. Connect the Electronic Service Tool to The electronic service tool communicate with the ECM.
the Service Tool Connector. Proceed to troubleshooting without a diagnos-
tic code Troubleshooting, “Electronic Service
Tool Does Not Communicate”.
Result: The electronic service tool communi-

cates with the ECM. Proceed to Test Step 3.
3. Troubleshoot the Perkins Data Link for Perkins Data Link Result: Perkins Data Link does not connect.
possible problems. Refer to Troubleshooting, “Data Link Circuit -
Test”.
Result: Perkins Data Link connects. Proceed

to Test Step 4.
4. Troubleshoot the CAN Data Link (if CAN Data Link Result: CAN Data Link does not connect. Re-
equipped) for possible problems. fer to Troubleshooting, “CAN Data Link Circuit
- Test”.
Result: CAN Data Link connects. Return to

service.
i06301360
Engine Cranks but Does Not

Start
Download the “Product Status Report” from the

engine Electronic Control Module (ECM) before
performing any troubleshooting or clearing diagnostic
trouble codes.
Note: If the engine will not start and the electronic

service tool will not communicate with the ECM, the
problem is most likely with the electrical power supply
to the ECM. Refer to Troubleshooting, “Electrical
Power Supply - Test”.
62 UENR4542-04
Table 23
1. Inspection of the Fuel Supply Fuel Level Result : The fuel level is OK.
A. Visually check the fuel level in the fuel tank. Do not rely Proceed to Test Step 2.
on the fuel gauge only.
Result : The fuel level is NOT OK.
B. Ensure that the fuel supply valve (if equipped) is in the
full OPEN position. Repair : Fill the tank.
STOP
2. Check the Engine Shutdown Switches if Applicable Engine Shutdown Result : The switches are in the OFF position.
Switches
A. The engine shutdown switches must be in the OFF Proceed to Test Step 3.
position.
Result : The switches are not in the OFF position.
B. Use the electronic service tool to verify the status of the
engine shutdown switches. When a shutdown occurs, the Repair : Turn the switches to the OFF position.
keyswitch must be turned to the OFF position for at least 15
seconds before restarting the engine. STOP
3. Check the Engine Starting Aids if Applicable Starting Aids Result : The starting aid is operating correctly.
A. If cold ambient conditions exist, check the operation of Proceed to Test Step 4.
the starting aids. Verify that the starting aid is operating
correctly. Result : The starting aid is not operating correctly.
Repair : Refer to the appropriate circuit test in order to trou-

bleshoot the starting aid.
4. Restrictions in the Air Inlet and Exhaust System Air and Exhaust Result : There are no system restrictions.
System
A. Check for an air filter restriction indicator. Restrictions Proceed to Test Step 5.
B. Check the air inlet and exhaust system for restrictions Result : There are system restrictions.
and/or leaks.
Refer to Testing and Adjusting, “Air Inlet and Exhaust System
- Inspect” for more information on air system restrictions.
Repair : Replace plugged air filters. Refer to the Operation

and Maintenance Manual for the correct procedure.
5. Check for Activation of the Theft Deterrent System if Theft Deterrent Result : The theft deterrent system is not active.
Applicable System
A. Verify that the theft deterrent system is not active.
Result : The theft deterrent system is active.
Repair : Turn the theft deterrent system OFF.
(continued)
UENR4542-04 63
(Table 23, contd)

6. Check the Coolant Temperature Sensor for Proper Coolant Tempera- Result : The sensor is operating properly.
Operation ture Sensor
A. The coolant temperature sensor must provide a correct
signal in order for cold mode operation to operate correctly. Result : The sensor is not operating properly.
Refer to Cold Mode Operation within the Systems Opera-
tion, “General Information”. Repair : Refer to Troubleshooting, “Sensor Signal (Analog,
Passive) - Test” for troubleshooting information.
B. Verify that the coolant temperature on the electronic serv-
ice tool is reasonable for the conditions that are present.
7. Check the Engine Speed Signal for Proper Operation Timing Signal Result : The timing sensor is operating properly.
A. Crank the engine and observe the engine speed on the Proceed to Test Step 8.
electronic service tool status screen. Refer to Troubleshoot-
ing, “Speed/Timing - Test” for additional information. Result : The timing sensor is not operating properly.
Upon initial cranking, the status for engine speed may indi- Repair : Refer to Troubleshooting, “Speed/Timing - Test” for
cate that the engine speed signal is abnormal. This mes- troubleshooting information.
sage will be replaced with an engine speed once the ECM
is able to calculate a speed from the signal.
8. Inspect the Low-Pressure Fuel System Low-Pressure Result : The low-pressure fuel system is not operating
Fuel System properly.
A. Inspect the fuel system. Refer to Systems Operation/
Testing and Adjusting, “Fuel System” for additional Repair : Make the necessary repairs. Return the engine to
information. service.
B. Cold weather adversely affects the characteristics of the

fuel. Refer to the engines Operation and Maintenance Man-
ual for information on improving the characteristics of the
fuel during cold-weather operation.
C. Check fuel quality. Refer to Systems Operation/Testing

and Adjusting, “Fuel System” for the proper procedure.
Check the fuel tank for debris or foreign objects which may
block the fuel supply.
D. Check the filtered fuel pressure while the engine is being

cranked. Refer to Systems Operation/Testing and Adjusting,
“Fuel System” for the test procedure and for the correct
pressure values.
If the fuel pressure is low, replace the fuel filters. Clean the
primary filter/water separator of debris. Refer to the Opera-
tion and Maintenance Manual for details.
E. Check for the proper operation of the fuel transfer pump.

Refer to Systems Operation/Testing and Adjusting, “Fuel
System” for test information.
i05963806
Engine Does Not Crank
Use this procedure to troubleshoot an engine that will

not crank.
64 UENR4542-04
Table 24
1. Inspection of the Batteries and Battery Cables Batteries are OK Result The batteries and cables are OK.
A. Inspect the main power switch, battery posts, and battery ca- Proceed to Test Step 2.
bles for loose connections and for corrosion. If the battery ca-
bles are corroded, remove the battery cables and clean the Result The batteries and cables are not OK.
battery cables. Tighten any loose connections.
Make the necessary repairs. STOP.
B. Inspect the batteries.
C. Charge the batteries.
D. Test the batteries. Systems Operation, Testing and Adjusting,

“Battery - Test”.
2. Switches and/or Circuit Breakers (if applicable) Switches and/or Result The switches and/or circuit breakers are OK.
circuit breakers
A. If equipped, check any switches and/or circuit breakers that are OK Proceed to Test Step 3.
may interfere with the engine cranking. Refer to the applications
electrical schematic for additional information. Result The switches and/or circuit breakers are not OK.
3. Starting Motor Solenoid and Starting Circuit Starting motor Result The starting motor solenoid and circuit are OK.
solenoid and cir-
Test the operation of the starting motor circuit. Refer to Systems cuit are OK. Proceed to Test Step 4.
Operation/Testing and Adjusting, “Electrical System” for addi-
tional information. Result The starting motor solenoid and circuit are not OK.
4. Inspect the Starter Pinion and Flywheel Ring Gear Starter pinion Result The starter pinion and flywheel ring gear are OK.
and flywheel ring
A. Test the operation of the starting motor. gear are OK Proceed to Test Step 5.
B. Check the pinion clearance. Inspect the pinion and the fly- Result The starter pinion and flywheel ring gear are not
wheel ring gear for damage. Refer to Systems Operation/Test- OK.
ing and Adjusting, “Electrical System” for additional information.
(continued)
UENR4542-04 65
(Table 24, contd)

5. Inspect Engine Accessories and the Transmission (if Engine accesso- Result The engine accessories and transmission are OK.
applicable) ries and trans-
mission are OK Proceed to Test Step 6.
A. Ensure free movement of the driveline.
Result The engine accessories and transmission are not
B. Remove any engine accessories that may lock up the engine OK.
and inspect any engine accessories that may lock up the
engine. Make the necessary repairs. STOP.
The following list illustrates examples of engine accessories that

may lock up the engine:
1. Hydraulic pump that is driven from the rear gear group

2. Air compressor
3. Engine oil pump
4. Other components that are driven by the engine
6. Hydraulic Cylinder Lock Hydraulic cylin- Result The engine has hydraulic cylinder lock.
der lock
A. If an injector has been replaced, evacuate any fluids from the Make the necessary repairs. STOP.
cylinder and attempt to start the engine. Fuel will flow from the
cylinder head into the cylinders when a unit injector is removed.
B. If the engine will not start, check for fluid in the cylinders (hy-
draulic cylinder lock) by removing the individual unit injectors.
Check for damaged seals. Determine the type of fluid that
locked up the cylinder.
C. If there was excessive fuel in the cylinder, replace the seals

and reinstall the injector. Drain any excess fuel from the cylinder
head.
D. If a mechanical problem is suspected, disassemble the en-

gine. Refer to the Disassembly and Assembly manual. Inspect
the internal components for the following conditions:
1. Seizure
2. Broken components
3. Bent components
i06251981 Recommended Actions

Engine Has Early Wear Note: The procedures have been listed in order of
Probable Causes
• Incorrect maintenance intervals and/or incorrect
oil
• Contaminated engine oil
• Low oil pressure

• Leaks in the air system
• Inspect the fuel filters for contamination.

66 UENR4542-04
Table 25
1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
intervals recommended by the engines Operation and Mainte-
A. Use engine oil that is recommended and change the engine oil nance Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.
Result: The engine oil was not changed at the interval

that is recommended by the engines Operation and Main-
tenance Manual.
Repair: Use at least the minimum recommended grade

of oil. refer to the Operation and Maintenance Manual.
Change the engine oil at the interval that is recom-

mended. Repair or replace any damaged parts.
2. Contaminated Engine Oil Contamination Result: The oil is contaminated.
A. Check the engine oil for contamination. Repair: Determine the reason for any contamination of
the engine oil and make the necessary repairs. Drain the
B. Check the oil filter bypass valve. crankcase and refill the crankcase with clean engine oil.
Install new engine oil filters. Refer to the engines Opera-
If the oil filter bypass valve is open, the oil will not be filtered. tion and Maintenance Manual.
Check the oil filter bypass valve for a weak spring or for a broken
spring. If the spring is broken, replace the spring. Verify that the oil Result: The oil is not contaminated.
bypass valve is operating correctly. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 3.
3. Low Oil Pressure Restriction Result: The inlet tube has a restriction.
A. Engine oil that is contaminated with another liquid can cause Repair: Clear the obstruction. Verify the repair.
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil. Result: The inlet tube does not have a restriction.
B. The inlet screen of the suction tube for the engine oil pump can Proceed to Test Step 4.
have a restriction. This restriction will cause cavitation and a loss
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.
When some components of the engine show wear in a short time,

the cause can be a restriction in a passage for engine oil. An indi-
cator for the engine oil pressure may indicate sufficient pressure,
but a component is worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.
(continued)
UENR4542-04 67
(Table 25, contd)

4. Leaks in Air System Air leak Result: There are no air leaks.
A. A leak in the air intake system may allow unfiltered air into the Proceed to Test Step 5.
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the Result: There are air leaks.
connections.
Repair: Repair any leaks.
5. Inspect the Fuel Filters for Contamination Fuel filters Result: The fuel has contamination.
A. Remove the fuel filters. Inspect the fuel filters for contamina- Repair: Determine the cause of any contamination and
tion. Contaminants in the fuel such as hydrogen sulfide and sulfur make the necessary repairs.
can lead to the formation of acids in the crankcase. Obtain a fuel
analysis. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.

steps are listed.
i06668262
Engine Has Mechanical Noise

(Knock)
Probable Causes
• Electrical connections
• Fuel injection
• Fuel quality
• Proper lubrication
• Isolate the source of the noise.

• Gear train and lower end components

• Crankshaft
Recommended Actions
68 UENR4542-04
Table 26
1. Active Codes and Logged Codes Codes Result: There are active codes.
A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continuing
and the Electronic Control Module (ECM). Refer to Troubleshoot- with this procedure.
ing, “Electronic Service Tools”, if necessary.
Result: There are no active codes.
B. Check for active diagnostic codes.
2. Electrical Connections Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair: Repair connectors that are suspect or replace con-
P2 connectors. Check for correct installation of the fuel injector nectors that are suspect.
connectors.
Perform the “Wiggle Test” on the electronic service tool.
Result: There are no suspect connectors.
3. Fuel Injection Diagnostic Result: The test was successful.

Test
A. Perform the “Injector Solenoid Test” on the electronic service Proceed to Test Step 4.
tool to determine if all the injector solenoids are being energized
by the ECM. Result: The test was not successful.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” Repair: Diagnose the problem and then repair the problem.
Reset all active codes and clear all logged codes.
service tool. Verify that the repair eliminated the problem.
4. Fuel Quality Fuel Result: The fuel quality is OK.
obtain a fuel analysis to confirm that the correct fuel is being used Result: The fuel quality is not OK.
for the engine. Refer to Systems Operation, Testing and Adjusting,
“Fuel System Quality Test” for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.
(continued)
UENR4542-04 69
(Table 26, contd)

5. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine
A. Check for proper lubrication of the valve components. Check
for sufficient lubrication between the injector tappets and the rock- Proceed to Test Step 6.
er arms.
C. Inspect the engine oil filters for ferrous material.
D. Check the engine oil for contamination.
6. Isolate the Source of the Noise Engine Result An engine accessory is the source of the noise.
accessory
A. If the source of the noise is the engine accessory, remove the Repair: Repair the engine accessory and/or replace the en-
suspect engine accessory. Inspect the suspect engine accessory. gine accessory, if necessary.
Result An engine accessory is not the source of the noise.
Excessive”.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items Repair: Make the necessary repairs, Verify that the repair
for damage: eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
(continued)
70 UENR4542-04
(Table 26, contd)

damaged.
Result: The gear train or lower end components are not

damaged.
9. Crankshaft Crankshaft Result: The crankshaft or the related components are dam-
aged or worn.
A. Inspect the crankshaft and the related components. Look for
worn thrust plates and wear on the crankshaft. Repair: Repair or replace any damaged parts. Verify that
the repair eliminated the problem.
B. Inspect the connecting rod bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in the correct
position.
C. Check the counterweight bolts.
i06668280
Engine Misfires, Runs Rough

or Is Unstable
Note: Refer to Troubleshooting, “Service Tool

Features” for information about service features.
Probable Causes
• Low quality fuel

• Fuel injectors
• Lack of lubrication
• Gear train and components of the lower end
Recommended Actions
UENR4542-04 71
Table 27
A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continuing
and the Electronic Control Module (ECM). Refer to Troubleshoot- with this procedure.
Troubleshoot any active codes before continuing with this
procedure.
2. Fuel Quality Fuel Result: The fuel quality is OK.
obtain a fuel analysis to confirm that the correct fuel is being used Result: The fuel quality is not OK.
for the engine. Refer to Systems Operation, Testing and Adjusting,
“Fuel Quality - Test” for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.
3. Fuel Injectors Diagnostic Result: The test was successful.

Test
If service has been performed on the engine fuel system recently, Proceed to Test Step 4.
verify that the injector trim files are correct. Use the electronic serv-
ice tool to check that the injector trim files are correct for the injec- Result: The test was not successful.
tors that are installed on the engine.
Repair: Diagnose the problem and then repair the problem.
A. Perform the “Injector Solenoid Test” on the electronic service
tool to determine if all the injector solenoids are being energized Reset all active codes and clear all logged codes.
by the ECM.
Verify that the repair eliminated the problem.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests”

service tool.
4. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Proceed to Test Step 5.
arms.
C. Inspect the engine oil filters for ferrous material.
D. Check the engine oil for contamination.
(continued)
72 UENR4542-04
(Table 27, contd)

Excessive”.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items Repair:Make the necessary repairs, Verify that the repair
for damage: eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
damaged.

steps are listed.
i07192433
Engine Overspeeds
Use this procedure to troubleshoot an engine

overspeed or use this procedure if the following event
code is active.
UENR4542-04 73
Table 28
PDL Code Code Description

J1939 Code vary) Comments
190-0 E362 (3) Engine Overspeed The code requires factory passwords to be cleared.
190-15 E362 (1) Engine Overspeed The code is logged.
190–16 E362 (2) Engine Overspeed Fuel injection is disabled when the engine speed is above high idle.
Probable Causes
• Proceeding down steep grades (if applicable)
• Correct operation of the turbocharger or
turbochargers
• Intake air
• Starting aids that are not operating properly
Recommended Actions
Table 29
1. Proceeding Down Steep Grades (If Applicable) Steep grades Result: Steep grades are the cause of the overspeed.
Engaging the engine brakes on a steep grade may be Repair: Control the engine speed during steep grades.
necessary.
Result: Steep grades are not the cause of the overspeed.
A. The operator needs to understand the proper operation of
the machine when using the engine brakes. Proceed to Test Step 2.
Not all applications have engine brakes.
2.Correct Operation of the Turbocharger or Turbocharger Result: A turbocharger is leaking oil into the inlet.
Turbochargers
Repair: Repair or replace the faulty turbocharger.
A. Check for proper operation of the turbocharger or
turbochargers. Result: A turbocharger is not leaking oil into the inlet.
B. Check for any oil that may be leaking into the air inlet. Proceed to Test Step 3.
3. Intake Air Air quality Result: The atmosphere has combustible gases.
A. Check for combustible gases in the surrounding Repair: Do not operate the engine in an environment with
atmosphere. combustible gases.
B. Check for proper operation of starting aids (if equipped).

74 UENR4542-04

steps are listed.
i06302649
Engine Shutdown Occurs

Intermittently
Note: Use this procedure only if the engine shuts

down completely during operation.
Probable Causes
• Air shutoff

• Unstable fuel supply
• Electrical connections
• Switches
• Circuit protection
• Engine speed/timing
Recommended Actions
Table 30
1. Air Shutoff Air shutoff Result: The air shutoff system is operating properly.
A. Check the operation of the air shutoff system. Proceed to Test Step 2.
Result: The air shutoff system is not operating properly.
Repair: Repair the air shutoff system. Refer to Troubleshoot-

ing, “Air Shutoff - Test” for troubleshooting information.
2. Active Codes and Logged Codes Codes Result: There are associated diagnostic trouble codes active
or logged.
A. Certain diagnostic codes and/or event codes may cause an
engine shutdown. Connect the electronic service tool and check Repair: Troubleshoot any active or logged associated diag-
for active codes and for logged codes. Troubleshoot any codes nostic trouble codes before continuing with this procedure.
that are present prior to continuing with this procedure.
Result: There are no associated diagnostic trouble codes ac-
tive or logged.
(continued)
UENR4542-04 75
(Table 30, contd)

3. Electrical Connections Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the Repair: Repair connectors that are suspect or replace con-
J2/P2 connectors. Check for correct installation of the fuel injec- nectors that are suspect.
tor connectors.
Perform the “Wiggle Test” on the electronic service tool.
Result: There are no suspect connectors.
4. Unstable Fuel Supply Fuel Result: The fuel quality is OK.
If there is an immediate engine shutdown, troubleshoot the elec- Proceed to Test Step 5.
trical connectors before proceeding with this procedure.
Result: The fuel quality is not OK.
A. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information. Repair: Replace the fuel. Verify that the repair eliminated the
problem.
Cold weather adversely affects the characteristics of the fuel.
Refer to the engine Operation and Maintenance Manual for in-
formation on improving the characteristics of the fuel during
cold-weather operation.
B. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
C. Check the filtered fuel pressure while the engine is being

cranked.
5. Electrical Connections Electrical Result: The electrical connections are OK.

connectors
A. Check the power and ground connections to the ECM. Refer Proceed to Test Step 6.
to Troubleshooting, “Electrical Power Supply - Test”.
Result: The electrical connections are not OK.
Repair: Repair or replace the damaged connectors. Verify

that the repair eliminated the problem.
6. Switches Switches Result: The shutdown switches and wiring are OK.
A. Check the keyswitch input to the ECM. Proceed to Test Step 7.
B. Check any engine shutdown switches and associated wiring. Result: The shutdown switches and wiring are not OK.
Repair: Make the necessary repairs, Verify that the repair

(continued)
76 UENR4542-04
(Table 30, contd)

7. Circuit Protection Circuit Result The circuit protection device is tripped.

protection
A. Inspect the wires and connectors to all circuit protection for Repair: Reset the circuit breakers if the circuit breakers are
the engine. tripped. If necessary, replace fuses (if equipped). Prior to re-
turning the engine to service, determine the condition that
B. Check the device for circuit protection. caused the circuit breaker to trip. Make the necessary repairs.
Result The circuit protection device is not tripped.
8. Engine Speed/Timing Speed/Timing Result: The Speed/Timing sensor circuit is not operating
properly.
A. Thoroughly inspect the connectors for the engine speed/tim-
ing sensors. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem. Refer to Troubleshooting, “Speed/
B. Crank the engine, if the engine starts and no speed timing co- Timing `- Test”
des are logged, the speed timing circuit is operating properly.

steps are listed.
i06255977
Engine Stalls at Low RPM

Probable Causes
• Incorrect parameters
• Air shut-off system

• Low-pressure fuel system
• Fuel injectors
• Engine accessories
• Parasitic loads
Recommended Actions
UENR4542-04 77
Table 31
1. Active Codes and Logged Codes Diagnostic Result: A code is active or logged.
code
A. Establish communication between the electronic service tool and Repair: Troubleshoot any active codes before continuing
the Electronic Control Module (ECM) . Refer to Troubleshooting, with this procedure.
“Electronic Service Tools”, if necessary.
Result: A code is not active or logged.
B. Determine if a code is active or logged.
2. Incorrect Parameters Parameters Result: The correct parameters are being used.
A. Use the electronic service tool to verify that the correct parame- Proceed to Test Step 3.
ters are being used. Refer to Troubleshooting, “Configuration Pa-
rameters” for additional information. Result: The correct parameters are not being used.
Repair: Configure the correct parameters.
3. Air Shutoff System (if equipped) Air shutoff Result: The air shutoff is operating correctly.
A. Check for proper operation of the air shutoff system. Refer to Proceed to Test Step 4.
Troubleshooting, “Air Shutoff - Test”.
Result: The air shutoff is not operating correctly.
Repair: Make the necessary repairs. Verify the repair.
4. Low Pressure Fuel System Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 5.
fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing and
Adjusting, “Fuel System - Inspect” for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer

to the engines Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather
operation.
D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.
(continued)
78 UENR4542-04
(Table 31, contd)

5. Fuel Injectors Diagnostic Test Result: The test was successful.
If service has been performed on the engine fuel system recently, Proceed to Test Step 6.
verify that the injector trim files are correct. Use the electronic serv-
ice tool to check that the injector trim files are correct for the injec- Result: The test was not successful.
tors that are installed on the engine.
A. Perform the “Injector Solenoid Test” on the electronic service tool problem.
in order to determine if all of the injector solenoids are being ener-
gized by the ECM. Reset all active codes and clear all logged codes.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” under Verify that the repair eliminated the problem.
the “Diagnostics” menu.

service tool.
6. Engine Accessories Engine Result: An engine accessory is creating an excessive

accessories load.
A. Inspect any engine accessories and the transmission (if
applicable). Repair: Repair the engine accessory.
Complete the procedure in the order in which the Recommended Actions

steps are listed.
i07192443 probability. Complete the procedures in order.
Engine Top Speed Is Not

Obtained
Note: If this fault occurs only under load, refer to

Troubleshooting, “Acceleration Is Poor or Throttle
Response Is Poor”.

Probable Causes
• Incorrect parameters
• Accessory and/or parasitic loads

• Incorrect flash file
• Restriction in the air inlet and exhaust system
• Correct operation of the turbocharger or

turbochargers
• Low-pressure fuel system

• Fuel injectors
UENR4542-04 79
Table 32
A. Establish communication between the electronic service Repair: Troubleshoot any active codes before continuing with
tool and the Electronic Control Module (ECM). Refer to Trou- this procedure.
bleshooting, “Electronic Service Tools”, if necessary.
2. Incorrect Parameters Parameters Result: The parameters are configured correctly.
A. Use the electronic service tool to verify that the correct en- Proceed to Test Step 3.
gine parameters are being used. Refer to Troubleshooting,
“Configuration Parameters” for additional information. Result: The parameters are not configured correctly.
B. Verify that all the parameters for parasitic loads are Repair: Correctly configure the parameters.
correct.
3. Accessory and/or Parasitic Loads Parasitic loads Result: There is not an excessive load on the engine.

A. Check all accessory equipment for problems that may cre-
ate excessive load on the engine. Result: There is an excessive load on the engine.
B. Check for any excess parasitic load on the engine. Repair: Diagnose the problem and then repair the problem.
4. Incorrect Flash File Flash file Result: The latest flash file is installed in the ECM.
A. Verify that the latest flash file is installed in the Electronic Proceed to Test Step 5.
Control Module (ECM). Refer to Troubleshooting, “ECM Soft-
ware - Install” for the proper procedure. Result: The latest flash file is not installed in the ECM.
Repair: Install the latest flash file. Verify that the repair elimi-
nated the problem.
5. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
A. Check the air filter restriction indicator, if equipped. Clean
plugged air filters or replace plugged air filters. Refer to the Repair: Make the necessary repairs, Verify that the repair
Operation and Maintenance Manual. eliminated the problem.
B. Check the air inlet and exhaust system for restrictions Result: There are no restrictions in the air inlet or exhaust
and/or leaks. system.
(continued)
80 UENR4542-04
(Table 32, contd)

6. Correct Operation of the Turbocharger or Turbocharger Result: The turbocharger or turbochargers are operating
Turbochargers properly.
A. Check for correct operation of the turbocharger or Proceed to Test Step 7.

turbochargers.
Result: The turbocharger or turbochargers are not operating

properly.
Repair: Repair or replace the faulty turbocharger. Verify that

the repair eliminated the problem.
7. Low-Pressure Fuel System Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on Proceed to Test Step 8.
the fuel gauge only.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Make the necessary repairs. Verify that the repair
eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Test-
ing and Adjusting, “Fuel System - Inspect” for additional
information.
Cold weather adversely affects the characteristics of the fuel.

Refer to the engines Operation and Maintenance Manual for
information on improving the characteristics of the fuel during
D. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low”
for the proper testing procedure.
8. Fuel Injectors Injector Solenoid Result: The test was successful.

Test or Cylinder
If service has been performed on the engine fuel system re- Cutout Test Return the unit to service.
cently, verify that the injector trim files are correct. Use the
electronic service tool to check that the injector trim files are Result: The test was not successful.
correct for the injectors that are installed on the engine.
Repair: Diagnose the problem and then repair the problem.
A. Perform the “Injector Solenoid Test” on the electronic serv-
ice tool to determine if all the injector solenoids are being Reset all active codes and clear all logged codes.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests”
C. Perform the “Automatic Cylinder Cutout Test” on the elec-

tronic service tool.
UENR4542-04 81

steps are listed.
i06255992
Engine Vibration Is Excessive
Probable Causes
• Inspect the vibration damper.
• Engine supports
• Driven equipment
• Engine misfiring
• Running rough
82 UENR4542-04
Recommended Actions
Table 33
1. Inspect the Vibration Damper Damper Result: The vibration damper or the mounting bolts are
damaged.
A. Clean any debris from around the damper. Check the vibration
damper for damage. Repair: Replace the damaged vibration damper or the dam-
aged mounting bolts.
B. Inspect the mounting bolts for damage and/or for wear. Refer to
the Disassembly and Assembly manual. Result: The vibration damper or the mounting bolts are not
damaged.
2. Engine Supports Engine Result: The mounts and brackets are loose and/or broken.
Supports
A. Inspect the mounts and the brackets while you run the engine Repair: Replace the mounts and brackets that are loose
through the speed range. Look for mounts and brackets that are and/or broken.
loose and/or broken.
Result: The mounts and brackets are not loose and/or
B. Check the alignment of the following before operating the en- broken.
gine under load for any length of time:
1. Mounts
2. Coupling
3. Driven Equipment Driven Result: The driven equipment and the alignment are OK.
equipment
A. Inspect the mounting bolts for the driven equipment. Inspect the Repair: Refer to Troubleshooting, “Engine Misfires, Runs
alignment and the balance of the driven equipment. Rough, or Is Unstable”, for more troubleshooting
information.
B. Inspect the coupling.
Result The driven equipment and the alignment are not OK.
Repair: Repair or replace the driven equipment.
Complete the procedure in the order in which the • Valve adjustment

steps are listed.
i07192863
Exhaust Has Excessive Black

Smoke
Check for the following problems if there is excessive

black exhaust smoke.
Probable Causes
• Air inlet or exhaust system
• Atmospheric pressure sensor

• Flash file
• Fuel quality
UENR4542-04 83
Recommended Actions
Table 34
1. Air Inlet or Exhaust System Air Inlet or Ex- Result: There are no signs of damage or failure in the air inlet
haust System or exhaust system.
A. Check the air inlet system for restrictions and/or for leaks. Proceed to Test Step 2.
B. Check for an air filter restriction. Result: There are signs of damage or failure in the air inlet or
exhaust system.
C. Perform a visual inspection of the system for restrictions
and/or for leaks in the air inlet piping. Repair: Repair the air inlet or exhaust system.
D. Ensure that the turbocharger or turbochargers are in good

repair.
E. Check the exhaust system for restrictions.
2. Atmospheric Pressure Sensor Atmospheric Result: There are no codes present for the Atmospheric Pres-
Pressure sure Sensor.
A. Remove the sensor. Sensor
B. Remove debris, moisture, or ice from the sensor.
C. Install the sensor. Result: There are codes present for the Atmospheric Pres-
sure Sensor.
D. Check the electronic service tool for active diagnostic codes
on the sensor. If no active diagnostic code exists, the sensor Repair: Troubleshoot the codes before continuing with this
may be used. The correct reading for the atmospheric pres- procedure.
sure is between 50 kPa (7.25 psi) and 100 kPa (14.5 psi).
3. Flash File Flash File Result: The latest flash file is installed.
A. Verify that the latest flash file is installed. Refer to Trouble- Proceed to Test Step 4.
shooting, “ECM Software - Install” for information.
Result The latest flash file is not installed.
Repair: Install the correct flash file. Verify that the problem
has been resolved.
(continued)
84 UENR4542-04
(Table 34, contd)

4. Fuel Quality Fuel Quality Result The fuel quality is within the engine specifications.
A. Cold weather adversely affects the characteristics of the Proceed to Test Step 5.
fuel. Refer to Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation. Result The fuel quality is not within the engine specifications.
Repair: Replace the fuel with fuel that is within the engine
specifications.
Verify that the problem has been resolved.
5. Valve Adjustment Valve Result The valve adjustment is not within engine
Adjustment specifications.
A. Check the valve adjustment. Refer to Systems Operation/
Testing and Adjusting for information that is related to valve Repair: Make the appropriate adjustment. Verify that the prob-
adjustments. lem has been resolved.
i06534858
Exhaust Has Excessive White

Smoke
Note: Some white smoke may be present during cold

start-up conditions when the engine is operating
normally. If the white smoke persists, there may be a
problem.

Probable Causes
• Active codes
• Oil in the exhaust system
• Cold mode operation (if applicable). Refer to

"Cold Mode Operation" within the Systems
Operation, “General Information”.
• Starting aids (if applicable)

• Noncurrent flash file
• Cooling system
• Unstable fuel injection
Recommended Actions
UENR4542-04 85
Table 35
1. Active Codes and Logged Codes Diagnostic code Result: A code is active or logged.
A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continu-
and the Electronic Control Module (ECM) . Refer to Troubleshoot- ing with this procedure.
Result: A code is not active or logged.
B. Determine if a code is active or logged.
2. Oil in the Exhaust System Oil in the exhaust Result: The exhaust system contains oil.
system
A. Check for oil in the exhaust system. Repair: Determine the cause of oil in the exhaust sys-
tem and make the necessary repairs. If necessary, refer
to Troubleshooting, “Exhaust System Contains Oil”.
Result: The exhaust system does not contain oil.
3. Clean Oil from the Exhaust System Oil in the exhaust Result: Oil has been cleaned from the exhaust system
system and the white smoke has dissipated.
A. Remove excess oil from piping with a clean cloth.
Return the unit to service.
B. Operate the engine at elevated idle (1500 RPM) for 10
minutes. Result: Oil has been cleaned from the exhaust system
but the white smoke did not dissipate.
4. Cold Mode Operation (if applicable) Cold mode Result: The engine is operating in cold mode.
During cold mode operation, condensation may be present and is This function is normal operation. Return the engine to
normal. service.
A. Cold mode is activated whenever the engine coolant tempera- Result: The engine is not operating in cold mode.
ture falls below a predetermined value. Monitor the status screen
on the electronic service tool to verify that the engine has exited Proceed to Test Step 5.
cold mode. Observe the reading for coolant temperature on the
electronic service tool.
5. Starting Aids (If Applicable) Starting aid Result: The starting aid is operating correctly.
A. If cold ambient conditions exist, check operation of starting Proceed to Test Step 6.
aids. Verify that the starting aid is operating correctly. Refer to the
appropriate circuit test for information that is related to trouble- Result: The starting aid is not operating correctly.
shooting the starting aid.
Repair: Make the necessary repairs. Verify that the re-
B. If an ether start aid is not installed, check the configuration pair corrected the problem.
screen on the electronic service tool to verify that ether is not
enabled.
(continued)
86 UENR4542-04
(Table 35, contd)

6. Noncurrent Flash File Flash file Result: The latest flash file is installed.
A. Verify that the latest flash file is installed in the ECM. Refer to Proceed to Test Step 7.
Troubleshooting, “ECM Software - Install” for the proper
procedure. Result: The latest flash file is not installed.
Repair: Install the latest flash file. Verify that the repair
7. Cooling System Internal coolant Result: There is an internal coolant leak.

leak
A. Check for an internal coolant leak into the cylinder and/or the Repair: Make the necessary repairs. Verify that the re-
exhaust. Refer to Systems Operation/Testing and Adjusting, pair eliminated the problem.
“Cooling System”.
Result: There is not an internal coolant leak.
8. Unstable Fuel Supply Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 9.
fuel gauge only.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information.
Cold weather adversely affects the characteristics of the fuel. Re-

fer to the engines Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation.
D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.
E. Check the filtered fuel pressure whilst the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.
9. Fuel Injectors Injector Solenoid Result: The test was successful.

Test or Cylinder
If service has been performed on the engine fuel system recently, Cutout Test Return the unit to service.
verify that the injector trim files are correct. Use the electronic
service tool to check that the injector trim files are correct for the Result: The test was not successful.
injectors that are installed on the engine.
A. Perform the “Injector Solenoid Test” on the electronic service problem.
tool to determine if all the injector solenoids are being energized
by the ECM. Reset all active codes and clear all logged codes.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” Verify that the repair eliminated the problem.

service tool.
UENR4542-04 87

steps are listed.
i07192880
Exhaust System Contains Oil
Probable Causes
• Failed turbocharger seals
• Worn valve guide seals or faulty valve guide seals
• Worn valve guides

• Worn piston rings
• Extended idle times
Recommended Actions
Note: After the repair has been made, the oil should
be cleaned from the exhaust system. To clean the oil
from the exhaust system, perform the following
procedure:
1. Remove excess oil from piping with a clean cloth.

2. Operate the engine at elevated idle (1500 RPM)
for 10 minutes.
If white smoke dissipates, return machine to work.
If white smoke does not dissipate, Contact the Dealer
Solutions Network (DSN).
Table 36
1. Failed Turbocharger Seals Turbo seals Result: Oil is present in the inlet or exhaust manifold.
A. Check the inlet manifold and the exhaust manifold for oil. Repair: Replace the faulty turbocharger. Verify the repair.
Result: Oil is not present in the inlet or exhaust manifold.
2. Worn Valve Guide Seals or Faulty Valve Guide Seals Valve guide Result: The valve guide seals are damaged.
seals
A. Inspect the valve guide seals for wear and for damage. Repair: Replace the valve guide seals. Verify the repair.
Result: The valve guide seals are not damaged.
(continued)
88 UENR4542-04
(Table 36, contd)

3. Worn Valve Guides Valve guides Result: The valve guides are worn.
A. Inspect the valve guides for wear. Refer to the Specification Repair: If necessary, recondition the cylinder head. Verify
manual for the maximum permissible wear of the valve guides. the repair.
Result: The valve guides are not worn.
4. Worn Piston Rings Piston rings Result The piston rings are worn.
A. Piston rings that have excessive wear can cause too much Repair: Replace the piston rings. Verify the repair.
pressure in the crankcase. The additional pressure in the crank-
case will cause more than the normal amount of crankcase blowby Result The piston rings are not worn.
from the crankcase breather.
B. Inspect piston rings
5. Extended Idle Times Idle times Result The idle times are extensive.
A. Extended idle times will allow oil to pass into the exhaust Repair: Reduce the idle times.
system.

steps are listed.
i06981568
Exhaust Temperature Is High
The Engine Control Module (ECM) monitors the

following parameters to calculate an exhaust
temperature:
• Barometric pressure
• Intake manifold air temperature
• Engine speed
Certain operating conditions may cause the
calculated exhaust temperature to increase to a level
that may damage engine components. If a high
exhaust temperature occurs, the ECM derates the
engine to reduce the calculated exhaust temperature.
The engine is derated only to a level that allows the
calculated exhaust temperature to return to an
acceptable level.
Table 37
173-16 E194 (2) High Exhaust Temperature The code is logged.

Engine power is reduced.
UENR4542-04 89
Table 38
Associated Diagnostic Trouble Codes
J1939 Code PDL Code

108-3 274-3
108-4 274-4
Note: The electronic service tool will report the status

for atmospheric pressure as the ambient barometric
pressure. The readings for the turbocharger inlet
pressure sensor will be approximately the same
value that is reported by the atmospheric pressure
sensor. The approximate same value readings will
occur when the engine is not running. If the readings
do not agree, troubleshoot the sensor circuit for the
suspect sensor. Refer to Troubleshooting, “Sensor
Signal (Analog, Active) - Test”.
Probable Causes
• Associated codes
• Boost Leak
• Engine operating conditions

• High altitude
• Obstructed aftercooler
Note: Information from this histogram is to be used
with active and logged diagnostic trouble codes. This
histogram is informational if no diagnostic codes are
active or logged.
90 UENR4542-04
Recommended Actions
Table 39
1. Check for Associated Diagnostic Codes Associated di- Result: An associated diagnostic code is active or logged.
agnostic
A. Establish communication between the electronic service tool codes Repair: Troubleshoot the associated code. Refer to Trou-
and the ECM . Refer to Troubleshooting, “Electronic Service bleshooting, “Diagnostic Trouble Codes” to troubleshoot the
Tools”, if necessary. associated diagnostic code.
B. Determine if a code is active or logged. Result: An associated diagnostic code is not active or
logged.
Table 40
DTC with associ- Data logged in this Interpretation
ated derate? histogram?
Derate was probably

caused by the ex-
No Yes
haust temperature
derate.
There may be multi-
ple causes for de-
rate since the
exhaust tempera-
ture histogram only
logs data when
there is the largest
Yes Yes
derate. Another de-
rate may have been
active due to a diag-
nostic trouble code,
but a larger exhaust
temperature derate
was applied.
Derate was probably

not caused by the
Yes No
exhaust tempera-
ture derate.
Note: Information from this histogram is to be used

with active and logged diagnostic trouble codes. This
histogram is informational if no diagnostic codes are
active or logged.
UENR4542-04 91
Example of the electronic service tool screenshot of the histogram. This histogram is populated when the engine
system has calculated a condition in which high exhaust temperatures are present.
Table 41
2. Check for Boost Leakage Boost leaks Result: Boost leakage was found.
A. Apply a light load to the engine and check for boost leakage. Repair: Repair the leaks. Return the unit to service.
Result: Boost leakage was not found.
3. Check the Engine Operating Conditions Normal Result: The code was logged during a heavy load.
operation
A. Check the histogram to determine if the high exhaust tempera- Repair: Reduce the load on the engine. Return the unit to
ture was due to normal operation. service.
When possible, interview the operator. Determine if the engine is
being operated under heavy load. Ensure that the engine is being Result: The code was not logged during a heavy load.
operated at the proper engine speed.
If derates are suspected, reset histogram and return the unit to
service. If the histogram repopulates without fault codes, the en-
gine derate was under normal engine operation.
(continued)
92 UENR4542-04
(Table 41, contd)

4. Check the Engine Operating Altitude High opera- Result: The engine was operating at high altitudes.
tional
A. Check the engine operating altitude. altitudes Repair: The high exhaust temperature was due to high alti-
tudes. Return the unit to service.
High altitudes can cause high exhaust temperatures, consider the
operational altitude when troubleshooting a high exhaust temper- Result: The engine was not operating at high altitudes.
ature. High exhaust temperatures are associated with high opera-
tional altitudes. Proceed to Test Step 5.
When operating below 5500ft and the ambient temperature is be-

low 30° C (85° F), altitude should not cause a high exhaust tem-
perature derate.
5. Check for an Obstructed Aftercooler Obstructed Result: The engine aftercooler was obstructed.
aftercooler
A. The intake manifold air temperature can increase if the flow Repair: Clear any obstructions. Return the unit to service.
through the aftercooler is obstructed. Check the aftercooler for ob-
structions or debris. Ensure that the flow of air or coolant through
the aftercooler is adequate.
i06256144
Fuel Consumption Is
Excessive
Probable Causes
• Look for excessive idle or high load
• Logged diagnostic codes or active diagnostic
codes
• Fuel quality

• Calibration procedure of the engine speed/timing
• Unstable injection system
• Restriction in the air inlet and exhaust

• Check for damaged accessory equipment
Recommended Actions
UENR4542-04 93
Table 42
1. Excessive Idle or High Load Idle time or Result: The idle times or load was excessive.
load
A. Use the electronic service tool to check the “Current Totals” for Repair: Reduce idle times or load.
excessive idle time and/or for a high load factor. These factors
would be indicative of poor operating habits. Result: The idle times or load was not excessive.
2. Diagnostic Codes Codes Result: There are logged or active diagnostic codes.
A. Check for logged diagnostic codes or active diagnostic codes. Repair: Troubleshoot any logged or active diagnostic codes
If a diagnostic code is logged or active refer to Troubleshooting, before continuing with this procedure. Refer to Troubleshoot-
“Diagnostic Trouble Codes” for more information. ing, “Diagnostic Trouble Codes” for more information.
Result: There are no logged or active diagnostic codes.
3. Fuel Quality Fuel quality Result: The fuel quality meets specifications.
A. The grade of the fuel affects the rate of fuel consumption. Refer Proceed to Test Step 4.
to the engines Operation and Maintenance Manual for additional
information. Result The fuel quality does not meet specifications.
Cold weather adversely affects the characteristics of the fuel. Re- Repair: Replace the fuel with fuel that meets the specifica-
fer to the Operation and Maintenance Manual for information on tions in the Operation and Maintenance Manual.
improving the characteristics of the fuel during cold-weather
operation.
4. Calibration Procedure of the Engine Speed/Timing Calibration Result The speed timing calibration was performed.
A. Perform a speed/timing sensor calibration. Refer to the calibra- Proceed to Test Step 5.
tion procedure Troubleshooting, “Timing - Calibrate”.
5. Unstable Injection Actuation System Injection Result The tests completed successfully.
actuation
A. Check for correct installation of the J1/P1 and J2/P2 Electronic Proceed to Test Step 6.
Control Module (ECM) connectors and the injector connectors.
Refer to Troubleshooting, “Electrical Connectors - Inspect”. Result The tests did not complete successfully.
B. Perform the “Injector Solenoid Test” on the electronic service Repair: Make the necessary repairs. Verify that the repair
tool in order to determine if all of the injector solenoids are being resolved the problem.
C. Perform the “Cylinder Cutout Test” on the electronic service tool

in order to identify any injectors that might be misfiring. Refer to
Troubleshooting, “Injector Solenoid - Test”.
(continued)
94 UENR4542-04
(Table 42, contd)

6. Restriction in the Air Inlet and Exhaust Restrictions Result There are restrictions in the air inlet or exhaust
system.
A. Inspect the air filter for a restriction.
Repair: Remove or repair the restrictions.
B. Check the air inlet and exhaust system for restrictions and/or
for leaks. Result There are no restrictions in the air inlet or exhaust
system.
7. Check for Damaged Accessory Equipment Accessory Result There is damaged accessory equipment.
equipment
A. Check all accessory equipment for problems that may create Repair: Remove or repair the accessory equipment.
excessive load on the engine.

steps are listed.
i06303417
Fuel Pressure Is High
The probable causes of high fuel pressure
• Fuel pressure sensor

• Fuel lines
• Fuel transfer pump

• Fuel return pressure regulator
Note: High fuel pressure may cause high fuel

temperatures. Troubleshoot a code for high fuel
pressure before troubleshooting a code for high fuel
temperature.
Use this procedure in order to troubleshoot high fuel
pressure. Use this procedure if one of the following
event codes is active. For information on the engine
monitoring system, refer to Troubleshooting,
Table 43

94-0 Engine Fuel Delivery Pressure : High - most se- The code is logged
E96 (3)
vere (3)
94-15 Engine Fuel Delivery Pressure : High - least severe The code is logged
E96 (1)
(1)
UENR4542-04 95
Table 44
1. Determine the Code Diagnostic trou- Result: One of the codes listed in Table 43 is present.
ble code
A. Connect the electronic service tool to the service tool connector. Proceed to Test Step 2.
Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
Result: A code other than those listed in Table 43 code
B. Determine if a diagnostic trouble code is present. is present.
Repair: Troubleshoot the code. Refer to the correct

troubleshooting procedure.
2. Verify the Operation of the Fuel Pressure Sensor Fuel pressure Result: The gauge value of the fuel pressure is within
137 kPa (20 psi) of the fuel pressure reading shown in
A. Turn the keyswitch to the OFF position. the electronic service tool.
B. Remove the fuel pressure sensor. Proceed to Test Step 3.
C. Install a suitable pressure gauge into the low-pressure fuel sys- Result: The gauge value of the fuel pressure is not
tem with a tee fitting in the port for the fuel pressure sensor. within 137 kPa (20 psi) of the fuel pressure reading
shown in the electronic service tool.
D. Connect the fuel pressure sensor to the tee fitting.
Repair: Replace the pressure sensor. Reset all active
E. Monitor the status for “Fuel Pressure” on the electronic service codes and clear all logged codes by cycling the key-
tool. switch to the OFF position. Verify that the problem has
been resolved.
F. Crank the engine.
If the problem is not resolved, proceed to Test Step 3.
G. Compare the pressure reading on the gauge to the pressure
reading on the electronic service tool.
96 UENR4542-04
Fuel supply lines
UENR4542-04 97
Return fuel line
Table 45
3. Inspect the Fuel Supply Lines Restrictions, Result: The fuel lines and the cooler (if equipped) are
pinching, and OK.
A. Visually inspect the fuel lines between the primary filter base swelling
and the inlet to the cylinder head. Also, inspect the fuel cooler, if Proceed to Test Step 4.
equipped. Inspect the fuel return line from the head to the fuel
tank. Inspect the lines for restrictions, pinching, and swelling. Result: The fuel lines and the cooler (if equipped) are
not OK.
Repair: Make the necessary repairs. Reset all active

codes and clear all logged codes by cycling the key-
switch to the OFF position. Verify that the problem has
been resolved.

98 UENR4542-04
(5) Return fuel pressure regulator
Table 46
4. Replace the Return Fuel Pressure Regulator Fuel pressure Result: The regulator was replaced. Reset all active
regulator codes and clear all logged codes by cycling the key-
A. Replace the fuel pressure regulator. switch to the OFF position. Verify that the problem is
resolved.

UENR4542-04 99
Typical fuel transfer pump
(6) Relief valve
Table 47
5. Inspect the Relief Valve for the Fuel Transfer Pump Relief valve Result: The relief valve is stuck CLOSED.
A. Inspect the relief valve for the transfer pump. The spring must Repair: Replace the fuel transfer pump. Reset all ac-
move freely. tive codes and clear all logged codes by cycling the
keyswitch to the OFF position. Verify that the problem
has been resolved.
Result: The relief valve is OK.
Repair: Clean the relief valve and reinstall the relief

valve. Reset all active codes and clear all logged codes
by cycling the keyswitch to the OFF position. Verify that
the problem has been resolved.
Complete the procedure in the order in which the Note: Some of the following codes may not be
steps are listed. applicable for certain applications.
i06304239
Fuel Pressure Is Low
Note: The low fuel pressure code may activate when

the water separator is being drained. Disregard the
code and toggle the keyswitch to clear the code.
Use this procedure in order to troubleshoot a low fuel
pressure event. Use this procedure if one of the
following event codes is active.
100 UENR4542-04
Table 48

Engine Fuel Delivery Pressure : Low - The code is logged.
94-1 E198 (3)
most severe (3) The engine may shut down
Engine Fuel Delivery Pressure : Low -

94-17 E198 (1) The code is logged.
least severe (1)
Engine Fuel Delivery Pressure : Low - The code is logged.

94-18 E198 (2)
moderate severity (2) The engine power will be derated.
Table 49
1. Determine the Code Codes Result: A diagnostic code listed in Table 48 is active.
A. Connect the electronic service tool to the service tool connector. Proceed to Test Step 2.
Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
Result: A diagnostic code other than those listed in Table
B. Check for active diagnostic codes. 48 is active.
Repair: Troubleshoot the additional diagnostic codes.

Refer to Troubleshooting, “Diagnostic Trouble Codes”.
2. Check the Fuel Level in the Tank Fuel level Result: The fuel level is OK.
A. Visually inspect the fuel level in the fuel tank. Ensure that the fuel Proceed to Test Step 3.
tank contains enough fuel in order to operate the engine.
Result: The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Fill the tank. Verify that the problem has been
resolved.
3. Inspect the Fuel System for Leaks Leaks in the Result: No leaks were found.
fuel system
A. Perform a visual inspection of the fuel system. Verify that there Proceed to Test Step 4.
are no fuel leaks. Inspect the fuel lines from the fuel transfer pump
to the secondary fuel filter base for restrictions. Refer to Systems Result: Leaks were found in the fuel system.
Operation/Testing and Adjusting, “Fuel System - Inspect” for addi-
tional information. Repair: Repair the leaks. Verify that the problem is
resolved.
Note: Cold weather adversely affects the

characteristics of the fuel. Refer to the engine
Operation and Maintenance Manual for information
on improving the characteristics of the fuel during
UENR4542-04 101
(1) Fuel temperature sensor (3) Fuel pressure sensor

(2) Fuel sampling port (4) Fuel filter base
Note: Do not use location (2) for measuring the fuel

pressure. Follow the steps below.
102 UENR4542-04
Table 50
4. Verify the Operation of the Fuel Pressure Sensor Pressure Result: The gauge value of the fuel pressure is within
sensor 69 kPa (10 psi) of the fuel pressure reading shown in the
A. Turn the keyswitch to the OFF position. electronic service tool.
B. Remove the fuel pressure sensor. Proceed to Test Step 5.
C. Install a suitable pressure gauge into the low-pressure fuel sys- Result: The gauge value of the fuel pressure is not within
tem with a tee fitting in the port for the fuel pressure sensor. 69 kPa (10 psi) of the fuel pressure reading shown in the
D. Connect the fuel pressure sensor to the tee fitting.
Repair: Replace the pressure sensor. Verify that the
E. Monitor the status for “Fuel Pressure” on the electronic service problem has been resolved.
tool.
F. Crank the engine.
G. Compare the pressure reading on the gauge to the pressure

reading on the electronic service tool.
5. Replace the Fuel Filters Fuel filters Result: The problem has been resolved.
A. Replace the primary filter, the secondary filter, and the tertiary Return the engine to service.
fuel filters.
The fuel system will need to be primed after the filters are re- Result: The problem has not been resolved.
placed. Refer to Operation and Maintenance Manual for the
correct procedure. Proceed to Test Step 6.
B. Reset all active codes by cycling the keyswitch to the OFF posi-
tion for 2 minutes.
6. Check for Air in the Fuel System Air in the Result: Air is in the system.
system
A. Check for air in the fuel. Refer to Systems Operation/Testing and Repair: Refer to Systems Operation/Testing and Adjust-
Adjusting, “Air in Fuel - Test” for the correct procedure ing, “Air in Fuel - Test” for the correct repairs.
Result: Air is not in the system.

UENR4542-04 103
(5) Anti-drain check valve (6) Fuel return pressure regulator
Table 51
7. Replace the Fuel Return Pressure Regulator Replace pres- Result: The problem has been resolved
sure regulator
A. Replace the fuel return pressure regulator. Return the engine to service.
B. Inspect the anti-drain check valve for proper operation. STOP
Result: The problem has not been resolved.
8. Replace the Transfer Pump Transfer pump Result: The transfer pump was replaced.
A. Replace the transfer pump. Reset all active codes and clear all logged codes by using
For information about testing the transfer pump, Refer to Testing the electronic service tool.
and Adjusting, “Fuel System Pressure - Test”.
Verify that the problem has been resolved.
STOP
Complete the procedure in the order in which the • Fuel level in the tank
steps are listed.
• Fuel temperature sensor
i06304313
• Fuel Cooler (if equipped)
Fuel Temperature Is High • Fuel return pressure regulator
• Restriction in the fuel lines
The probable causes of high fuel temperature • Fuel injector
• Associated codes
104 UENR4542-04
Use this procedure in order to troubleshoot high fuel

temperature. Use this procedure if one of the
following event codes is active.
Table 52
Diagnostic Trouble Code

The fuel temperature is above an ac-
ceptable level.
Engine Fuel Temperature 1 : High -
174-15 E363 (1) If equipped, the action lamp will
least severe (1)
illuminate.
The code is logged.
Engine Fuel Temperature 1 : High - The fuel temperature is above an ac-

174-16 E363 (2)
moderate severity (2) ceptable level.
If equipped, the action lamp will
Engine Fuel Temperature 1 : High - illuminate.
174-0 E363 (3) The code is logged.
most severe (3)
There may be a decrease in power.
Table 53
Associated Codes
J1939 Code PDL Code
94-1 E198 (3)
94-17 E198 (1)
94-18 E198 (2)
Table 54
1. Determine the Code Diagnostic trou- Result: An associated code is active or logged.
ble code
A. Check for active codes and check for logged codes on the elec- Repair: Troubleshoot any active codes before continu-
tronic service tool. ing with this procedure.
B. Check the electronic service tool for any associated codes that Result: An associated code is not active or logged.
are listed in Table 53 . Troubleshoot any active codes before con-
tinuing with this procedure. Proceed to Test Step 2.
2. Check the Fuel Level in the Fuel Tank Fuel level Result: The fuel level is acceptable.
A. Check the fuel level in the fuel tank. Proceed to Test Step 3.
Result: The fuel level is not acceptable.
Repair: Fill the tank. Verify that the problem has been
resolved. If the problem has not been resolved, proceed
to Test Step 3.
UENR4542-04 105
Fuel supply lines
106 UENR4542-04
Fuel return line
UENR4542-04 107
Table 55
3. Inspect the Fuel Supply Lines Dirt and debris or Result: The fuel lines and the cooler (if equipped) are
damage OK.
A. Visually inspect the fuel lines between the priming pump and
the inlet to the cylinder head. Also, inspect the fuel cooler for dirt, Proceed to Test Step 4.
debris, or damage, if equipped. Inspect the fuel return line from
the head to the fuel tank. Inspect the lines for restrictions, pinch- Result: The fuel lines and the cooler (if equipped) are
ing, and swelling. Refer to Systems Operation/Testing and Adjust- not OK.
ing, “Fuel System - Inspect” for additional information.
Repair: Replace damaged fuel lines and/or fuel cooler
B. Inspect the fuel cooler for dirt, debris, or damage, if equipped. (if equipped). Remove dirt or debris from fuel cooler fins
(if equipped). Verify that the problem has been resolved.
4. Replace the Temperature Sensor Active codes or Result: A 174 code is active or logged.
logged codes
A. Replace the fuel temperature sensor. Proceed to Test Step 5.
B. Check for active codes or logged codes. Result: A 174 code is not active or logged.

108 UENR4542-04
(1) Fuel return pressure regulator
Table 56
5. Fuel Return Pressure Regulator Pressure Result: The problem has been resolved.
regulator
A. Replace the fuel return pressure regulator. Return the unit to service.
Result: The problem has not been resolved.
6. Perform a Cylinder Cutout Test Test was not Result: The Cylinder Cutout Test was not successful.
successful
A. Perform a “Cylinder Cutout Test” in the electronic service tool. Repair: Replace the identified injectors. Verify that all
trim files are installed into the ECM correctly. Refer to
Troubleshooting, “Injector Trim File - Install”. Repeat the
“Fuel System Verification Test” after making the neces-
sary repairs. Repeat the process until all the injectors
are operating properly.
UENR4542-04 109

steps are listed.
i07192881
Inlet Air Temperature Is High
Use this procedure if one of the following diagnostic

codes is active:
Table 57
- E368 (1) High Inlet Air Temperature The inlet air temperature has exceeded the trip
point for the programmed delay time.
The code is logged.
- E368 (2) High Inlet Air Temperature The inlet air temperature has exceeded the trip
point for the programmed delay time.
The code is logged.
The engine power is derated.
Probable Causes
• Diagnostic codes
• High ambient air temperature
• Intake air restriction and/or high altitude

• Intake air from a heated area
Recommended Actions
110 UENR4542-04
Table 58
1. Diagnostic Codes Diagnostic Result: More diagnostic codes are active.

codes
A. Connect the electronic service tool to the diagnostic connector. Result: Troubleshoot any additional diagnostic codes be-
fore continuing with this procedure. Refer to Troubleshoot-
B. Check for active diagnostic codes on the electronic service tool. ing, Diagnostic Trouble Codes or refer to Troubleshooting,
Event Codes.
Repair: There are no additional active diagnostic codes.
2. High Ambient Air Temperature Ambient air Result: The ambient air temperature exceeds the capabil-
temperature ity of the cooling system.
A. Determine if the ambient air temperature is within the design
specifications for the cooling system. Repair: Operate the engine at a reduced load or operate
the engine at a reduced speed.
When possible, modify the cooling system to make the
system suitable for local conditions.
Result: The ambient air temperature is within the capabil-

ity of the cooling system.
3. Intake Air Restriction and/or High Altitude Intake manifold Result: The intake manifold pressure is below specifica-
pressure tions when the engine is operating under load.
Low air pressure at the air intake for the turbocharger or turbo-
chargers can be caused by a restriction in the air intake or a high Repair: Check for blocked air filters. Check for obstruc-
altitude. When the pressure of the intake air is low, the turbocharg- tions in the air intake. Replace the air filters or remove the
er or turbochargers work harder to achieve the desired intake obstruction from the air intake.
manifold pressure. This increases intake air temperature. Make sure that the settings for the engine are correct for
the altitude.
A. Measure the intake manifold pressure when the engine is oper-
ating under load. For specific data for the engine, refer to the “Per- Result: The intake manifold pressure is within specifica-
kins Technical Marketing Information” (PTMI) on the Perkins tions when the engine is operating under load.
secured web site.
4. Intake Air from a Heated Area Intake air Result : The air supply to the intake manifold is routed
routing from a heated area.
A. Ensure that the air inlet system is not receiving air from a heated
area. Repair: If necessary, relocate the air supply to the intake
manifold to the outside of the engine enclosure.
Result : The air supply to the intake manifold is not routed

from a heated area.
Repair: Check for air leaks in the pipe between the air in-
let and the inlet to the turbocharger compressor.
If the procedure did not correct the fault, contact the Deal-
er Solutions Network (DSN).
UENR4542-04 111
i07192884
Intake Manifold Air

Temperature Is High
This procedure covers the following diagnostic

codes:
Table 59

Engine Intake Manifold #1 The code indicates that the temperature of the intake air into the en-
105-0 E539 (3) Temperature : High - most se- gine has risen above a predetermined threshold. Engine power may
vere (3) be derated.
Engine Intake Manifold #1 Air The code indicates that the temperature of the intake air into the en-
105-15 E539(1) Temperature : High - least se- gine has risen above a predetermined threshold. Engine power may
vere (1) be derated.
Engine Intake Manifold #1 Air The code indicates that the temperature of the intake air into the en-
105-16 E539(2) Temperature : High - moder- gine has risen above a predetermined threshold. Engine power may
ate severity (2) be derated.
Intake manifold air temperature can be high for the

following reasons:
• High ambient air temperature
• High inlet air restriction and/or high altitude

• Restriction in the exhaust system
• Faulty inlet air temperature sensor and/or circuit
Table 60
1. Check for High Ambient Air Temperature Ambient air Results: The ambient air temperature is too high.
temperature
A. Determine if the ambient air temperature is within the Repair: Determine the cause of the high inlet air temperature.
design specifications for the inlet air system. Correct the situation, when possible.
Note: When ambient temperatures are too high for the Results: The ambient air temperature is OK.
rating of the inlet air system, there is not enough of a
temperature difference between the ambient air and inlet Proceed to Test Step 2.
air temperatures.
(continued)
112 UENR4542-04
(Table 60, contd)
2. Check for High Inlet Air Restriction and/or High Al- High Inlet Air Re- Results: The air filter is plugged. There is a restriction in the air
titude Operation striction and/or High inlet.
Altitude Operation
Note: When inlet air pressure is low, the turbocharger or Repair: Replace the air filters and/or remove the obstruction
turbochargers work harder to achieve the desired inlet from the air inlet.
manifold pressure. This increases inlet air temperature. Results: The engine is operating at high altitude.
A. Check for plugged air filters. Check for obstructions to
the air inlet. A restriction of the air that enters the engine Repair: A pressurized cooling system that has been designed
can cause high cylinder temperatures. High cylinder tem- for the higher altitudes must be used. Ensure that the engine is
peratures cause higher than normal temperatures in the configured for high altitude operation.
cooling system.
Results: The air inlet is OK. The engine is not operating at high
B. Consider high altitude operation. The cooling capabil- altitude.
ity of the cooling system is reduced at higher altitudes.
3. Check for Exhaust System Restriction Exhaust system Results: The exhaust system is restricted.
restriction
A. Check for a restriction in the exhaust system. Repair: Rectify the cause of the restriction.
Note: A restriction of the air that is coming out of the en- Results: The exhaust system is OK.
gine can cause high cylinder temperatures.
Repair: Contact the Dealer Solutions Network (DSN)
i07192888
Oil Consumption Is Excessive
Probable Causes
• Incorrect oil level in the crankcase
• Oil leaks on the outside of the engine
• Oil leaks in the combustion area of the cylinders

• Oil leakage at the injector
• Incorrect oil viscosity

• Condition of turbocharger or turbochargers
Recommended Actions
UENR4542-04 113
Table 61
1. Excessive Oil in the Crankcase Oil level Result: The oil level is correct.
A. Check the engine oil level. Too much oil in the engine crankcase Proceed to Test Step 2.
can cause the engine to consume oil.
Result: The oil level is high.
B. Ensure that the dipstick is properly calibrated and/or that the dip-
stick is correct for the application. Calibrate the dipstick and/or re- Repair: Remove excessive engine oil from the
place the dipstick. Refer to Systems Operation/Testing and crankcase.
Adjusting, “Lubrication System” for calibration of the dipstick gauge. Verify the repair.
2. Oil Leaks on the Outside of the Engine Oil leaks Result: There are oil leaks on the outside of the engine.
A. Check for oil leaks on the outside of the engine. Refer to Sys- Repair: Find the source of the oil leaks and make the
tems Operation/Testing and Adjusting, “Lubrication System”. necessary repairs.
Result: There are no oil leaks on the outside of the

engine.
3. Oil Leaks in the Combustion Area of the Cylinder Oil leaks Result: There are oil leaks in the combustion area of the
cylinder.
A. Check for oil leaks in the combustion area of the cylinders.
Repair: Make the necessary repairs. Replace parts, if
B. Check for excessive engine blowby. Excessive engine blowby necessary.
will cause unnecessary oil consumption. Excessive engine blowby
can also cause unnecessary engine wear. Result: There are no oil leaks in the combustion area of
the cylinder.
4. Oil Leakage At the Injector Oil leakage Result: There is oil leakage at the injector.
A. Check for the excessive transfer of oil from the high-pressure oil Repair: Make the necessary repairs. Replace parts, if
supply in the injector to the fuel return in the cylinder head. necessary.
There is not oil leakage at the injector.
5. Oil Viscosity Viscosity Result: The engine oil viscosity is correct.
A. Excessive consumption of engine oil can also result if engine oil Proceed to Test Step 6.
with the wrong viscosity is used. Engine oil with a thin viscosity can
be caused by fuel leakage into the crankcase or by increased en- Result: The engine oil viscosity is not correct.
gine temperature. Refer to the Operation and Maintenance Manual
for additional information. Repair: Replace the engine oil, Refer to the Operation
and Maintenance Manual for additional information.
6. Condition of Turbocharger Turbocharger Result: A turbocharger has leakage.

or
A. Check the turbocharger or turbochargers for leakage. turbochargers Repair: Make the necessary repairs. Replace parts, if
necessary.
114 UENR4542-04

steps are listed.
i06304518
Oil Contains Coolant
Emulsion is a mixture of oil and water. The water

occurs when condensation forms in the engine during
certain operating and seasonal conditions. The
emulsion may appear light in color. Emulsion may be
found in the following areas:
• Engine oil filler
• Engine oil level gauge

• Valve cover
• Crankcase ventilation system

The emulsion should disappear with increased
engine operating temperatures at higher load
conditions.
Probable Causes
• Leaks in the core of oil cooler
• Cracks in the turbocharger housing or center
section
• Leaks in the cylinder head gasket

• Damaged water seals
• Cracks in the cylinder head

• Cracks in a cylinder liner
• Liner seals
• Cracks in the cylinder block
UENR4542-04 115
Recommended Actions
Table 62
1. Leaks in Core of Oil Cooler Oil cooler Result: The oil cooler is leaking.
A. Check for leaks in the oil cooler core. Repair: Repair or replace the oil cooler.
Result: The oil cooler is not leaking.
2. Liquid Cooled Turbochargers Turbocharger Result The turbocharger housing or center section has
cracks.
A. Inspect the turbocharger housing and center section for
cracks. Repair: Make any repairs, as required.
Result The turbocharger housing or center section does not

have cracks.
3. Leaks in the Cylinder Head Gasket Head gasket Result The cylinder head gasket is leaking.
A. Inspect the cylinder head gasket for leaks. Repair: Replace the cylinder head gasket.
Result The cylinder head gasket is not leaking.
4. Damaged Water Seals Water seals Result The water seal is damaged.
A. Inspect the water seal for damage. Repair: Repair or replace the damaged seal.
Result The water seal is not damaged.
5. Cracks in the Cylinder Head Cylinder head Result The cylinder head is damaged.
A. Check for cracks in the cylinder head. Repair: Repair or replace the damaged cylinder head.
Result The cylinder head is not damaged.
(continued)
116 UENR4542-04
(Table 62, contd)

6. Cracks in a Cylinder Liner Cylinder liner Result The cylinder liner or seal is damaged or cracked.
and seals
A. Check for cracked cylinder liners. Repair: Repair or replace the damaged cylinder liner and
seal.
B. Check the liner seals for damage.
Result The cylinder liner or seal is not damaged or cracked.
7. Cracks in the Cylinder Block Cylinder liner Result The cylinder block is cracked.
A. Inspect the cylinder block for cracks. Repair: Repair or replace the damaged cylinder block.
8. Pressurize the Cooling System Leaks Result: The test indicates a drop in pressure.
A. Pressurize the cooling system. Refer to Systems Operation/ The leak still exists.
Testing and Adjusting, “Cooling System - Test”.
Repair: Make any repairs, as required.
Result: The test indicates that there is not a drop in

pressure.
Result: The engine oil was changed.

9. Change the Engine Oil Oil
A. Drain the engine oil.
B. Refill the engine with clean oil.
C. Run the engine until the engine is at normal operating

temperature.
D. Drain the engine oil, replace the oil filters, and refill the en-
gine with clean oil.
UENR4542-04 117
Complete the procedure in the order in which the Table 63

steps are listed. Oil Test Kits
i06260337 Region Part Number
North America and South 29990014

Oil Contains Fuel America
Rest of the world 29990011
Measuring Fuel Dilution 2. Follow the instructions that are supplied with the oil
test kit.
Diesel fuel is chemically similar to the lubricants that
are used in diesel engines. A slow fuel leak will blend 3. Obtain a sample of the oil from the engine. Refer to
the fuel into the oil. Normal operating temperatures Operation and Maintenance Manual, “Fluid
may cause volatile parts of the fuel to vaporize. The Recommendations - Engine Oil”.
fuel that remains in the oil is less volatile.
4. Complete the form that is included with the oil test
A closed cup flash test can be performed in order to
detect fuel dilution. The flash test is designed to kit.
measure the volatile parts of the fuel that are 5. Send the oil sample for analysis. Follow the
remaining in the oil. Detecting less volatile fuel is instructions that are included with the oil test kit.
difficult. The less volatile fuel reduces the accuracy of
the flash test.
Probable Causes
Since the flash test does not accurately detect
fuel dilution, do not use the flash test as the only • Leaking seals
measure of fuel dilution. Instead, verify the dilution
by the following methods: • Fuel injector tip
• Gas chromatograph fuel dilution test • Fuel transfer pump seal
• Oil viscosity • Cracked cylinder head
The test that uses a gas chromatograph is designed Recommended Actions

to measure fuel dilution in crankcase oils. The gas
chromatograph can identify the small chemical Note: The procedures have been listed in order of
differences between diesel fuel and lubricating oil. probability. Complete the procedures in order.
Even though the gas chromatograph provides a more
accurate measure of fuel dilution, always verify the
results with the viscosity test.
A significant level of fuel dilution reduces oil viscosity.
If an unacceptable level of fuel dilution is suspected,
the kinematic viscosity of the oil must be measured.
Fuel dilution that is greater than 10 percent will
usually cause viscosity that is less than the specified
viscosity grade. If the oil is still within the specified
viscosity grade, fuel dilution has not reached an
unacceptable level.
Verifying Fuel Dilution

Always verify fuel dilution by the combination of a
viscosity test and a gas chromatograph test. If the
result is in excess of 10 percent, investigate the
cause.
1. Obtain an oil test kit. Refer to table
118 UENR4542-04
Table 64
1. Leaking Seals O-ring seal Result: The injector O-ring seal is damaged.
A. Remove the injector from the affected cylinder and visually in- Repair: Replace the damaged seals. Install the injector onto
spect the injector O-ring seals for damage. the engine and confirm that the repair has resolved the
problem.
If leakage is found and the O-rings are in good repair, there may
be a problem with the injector. Replace the injector. Ensure that Result: The injector O-ring seal is not damaged.
the new trim files are installed. Refer to Troubleshooting, “Injector
Trim File - Install” for details. Use the electronic service tool to per- Proceed to Test Step 2.
form a “Fuel System Verification Test” . Refer to Troubleshooting,
“Injector Solenoid - Test” for details.
If the leakage is not located, add the appropriate dye to the fuel
tanks. Run the engine at high idle for several minutes. Shut down
the engine and remove the valve covers. Use a black light to
check for traces of dye around each injector.
2. Fuel Injector Tip Injector tip Result: The fuel injector tip is damaged.
A. Use the electronic service tool to perform the “Cylinder Cutout Repair: Replace the suspect injector.
Test” in order to identify any cylinders that may be overfueled.
Result: The fuel injector tip is not damaged.
B. A fuel injector tip that is broken or fractured is a possible cause
of a cylinder that is being overfueled. If a cylinder is identified by Proceed to Test Step 3.
the test, Remove the injector and check the injector tip for dam-
age. Check the fuel injector tip for cracks or breakage.
3. Fuel Transfer Pump Seal Pump seal Result: There is fuel leakage around the shaft seal.
A. Check for fuel leakage around the shaft seal for the fuel transfer Repair: Replace the fuel transfer pump.
pump. Ensure that the weep hole is not plugged.
Result There is not fuel leakage around the shaft seal.
4. Cracked Cylinder Head Cracked Result The internal passages for the fuel supply to the injec-
head tors are damaged.
A. Look for signs of damage to the internal passages for the fuel
supply to the injectors in the cylinder head. Check for pin hole Repair: Repair or replace the cylinder head.
leaks. Refer to Disassembly and Assembly.
Complete the procedure in the order in which the Use this procedure to troubleshoot low engine oil
steps are listed. pressure. Use this procedure if one of the following
event codes is active. For information on the engine
i06618651 monitoring system, refer to Troubleshooting,
Oil Pressure Is Low
Note: Severe slopes can cause low oil pressure. If

the machine is operated on severe slopes, the oil
level in the engine crankcase must be at the “FULL”
mark on the dipstick. Refer to Operation and
Maintenance Manual for details.
UENR4542-04 119
Table 65

Oil pressure is lower than the specified pressure for at least 4 seconds. Engine
power is reduced. A snapshot is triggered. The code is logged. Factory pass-
Engine Oil Pressure : Low -
100-1 E360 (3) words are required.
most severe (3)
After 30 seconds, the ECM will shut down the engine if the “Engine Monitoring
Mode” parameter is programmed to “Shut down” .
Engine Oil Pressure : Low - Oil pressure is below the specified pressure for at least 8 seconds. A snapshot is
100-17 E360 (1)
least severe (1) triggered. The code is logged. Engine performance is not affected.
Oil pressure is lower than the specified pressure for at least 4 seconds. Engine
power is reduced. A snapshot is triggered. The code is logged. Factory pass-
Engine Oil Pressure : Low -
100-18 E360 (2) words are required.
After 30 seconds, the Engine Control Module (ECM) will shut down the engine if
the “Engine Monitoring Mode” parameter is programmed to “Shut down” .
Probable Causes
• Low engine oil level
• Aeration in the oil
• Low oil viscosity

• Plugged Oil Filter
• Faulty oil pump

• Faulty engine oil pressure sensor
• Faulty bypass valve

• Damaged suction tube or cracked suction tube
• Excessive wear of engine components
Recommended Actions
Table 66
1. Engine Oil Level Oil Result: The engine oil level is low.
A. Check the engine oil level in the crankcase. Refer to the Opera- Repair: Add engine oil to obtain the correct engine oil level.
tion and Maintenance Manual for calibration of the dipstick gauge. Refer to Operation and Maintenance Manual, “Engine Oil” for
The oil level can possibly be too far below the oil pump supply the recommendations of engine oil.
tube. The oil pump cannot supply enough lubrication to the engine
components. Start the engine. Inspect the exterior of the engine for oil
leaks. Repair any oil leaks.
Result: The engine oil is not low.
(continued)
120 UENR4542-04
(Table 66, contd)
2. Aerated Oil Aeration Result: The oil is aerated.
A. Sample the engine oil for aeration. Proceed to Test Step 8.
Foamy oil on the dipstick is a good indication of aeration. Result: The oil is not aerated.
3. Oil Viscosity Oil viscosity Result: The oil viscosity is not correct.
A. Sample the engine oil viscosity. Repair: Replace the engine oil.
Refer to Operation and Maintenance Manual, “Engine Oil” for

the recommendations of engine oil. If the symptom is cor-
rected, return the unit to service. If the symptom still exists,
proceed to Test Step 4.
Result: The oil viscosity is correct.
4. Oil Filter Filter Result: The oil filter was changed.
A. Replace the engine oil filter. If the symptom is corrected, return the unit to service.
If the symptom still exists, proceed to Test Step 5.
5. Oil Pump Oil pressure Result: The oil pressure is meets specifications.
A. Manually check the engine oil pressure. Refer to Systems Oper- Proceed to Test Step 6.
ation/Testing and Adjusting, “Engine Oil Pressure - Test” for the
correct procedure. Result: The oil pressure does not meet specifications.
Repair: Replace the oil pump. If the symptom is corrected,

return the unit to service.
6. Engine Oil Pressure Sensor Sensor Result The pressure is within ±13.8 kPa (±2 psi).
A. Remove the oil pressure sensor. Proceed to Test Step 7.
B. Install a pipe “T” in the pressure sensor port. Result The pressure is not within ±13.8 kPa (±2 psi).
C. Install a manual gauge on one side of the pipe “T” . Install the oil Repair: Replace the sensor. If the symptom is corrected, re-
pressure sensor on the other side of the pipe “T” . turn the unit to service.
D. Start the engine and compare the two readings. The pressure If the symptom still exists, proceed to Test Step 7.
reading must be within ±13.8 kPa (±2 psi).
(continued)
UENR4542-04 121
(Table 66, contd)
7. Engine Oil Filter Bypass Filter base Result: The oil filter base was replaced.
A. Replace the oil filter base. If the symptom is corrected, return the unit to service.
8. Oil Pump Suction Tube Suction Result: The suction tube and seal are OK.
tube
A. Remove the oil pan. Proceed to Test Step 9.
B. Inspect the suction tube. Check the joints of the tube for cracks Result: The suction tube and seal are not OK.
or for a damaged O-ring seal at the connection to the pump.
C. Inspect the inlet screen of the suction tube for a restriction. This
restriction will cause cavitation and a loss of engine oil pressure.
9. Worn Engine Components Worn parts Result: There are worn engine components.
A. Remove the valve covers. Repair: Replace parts, if necessary.
B. Inspect the camshaft and bearings.
C. Remove the oil pan.
D. Excessive clearance at the crankshaft or camshaft bearings will

cause low engine oil pressure. Check the engine components for
excessive clearance. Also, inspect the piston cooling jets.
Complete the procedure in the order in which the • Excessive temperature of the turbocharger or
steps are listed. turbochargers that cause the engine derate
i07192892 Recommended Actions

If the problem only occurs under certain conditions,
Power Is Intermittently Low or test the engine under those conditions. Examples of
Power Cutout Is Intermittent certain conditions are high engine speed, full load,
and engine operating temperature. Troubleshooting
the symptoms under other conditions can give
misleading results.
Use this procedure only if the engine does not shut
down completely.
Probable Causes
• Check for active event codes that may derate
engine power
• Electrical connections not properly connected.

• Check for intermittent diagnostic codes
• Intermittent throttle signal

• Fuel system components
• Fuel supply pressure

• Restriction in the air inlet and exhaust system
122 UENR4542-04
Table 67
1. Check for Event Codes Event codes Result : An event code is active or logged.
A. Certain event codes may derate engine power. Connect the Repair :Troubleshoot any codes that are present be-
electronic service tool and check for active codes and/or for fore continuing with this procedure.
logged codes.
Result : An event code is not active or logged.
2. Check the Electrical Connections Electrical Result : The connectors are installed correctly.
connectors
A. Verify that the following connectors are installed correctly: Proceed to Test Step 3.
· Electrical connectors for the ECM Result: The connectors are not installed correctly.
· Connectors for the wiring harness under the valve cover
· Connectors for the engine speed/timing sensors Repair : Install the connectors correctly. Refer toTrou-
bleshooting, “Electrical Connectors - Inspect” for the
proper troubleshooting procedure.
3. Check for Intermittent Diagnostic Codes Diagnostic codes Result : Intermittent codes are present.
A. Certain diagnostic codes may cause poor performance. Con- Repair : Troubleshoot any codes that are present be-
nect the electronic service tool and check for active codes and/or fore continuing with this procedure.
for logged codes.
Result : Intermittent codes are not present.
4. Check the Intermittent Throttle Signal Throttle signal Result : The status for “Throttle Position” is stable.
A. Monitor the status for “Throttle Position” on the electronic serv- Proceed to Test Step 5.
ice tool.
Result : The status for “Throttle Position” is not
B. Verify that the status for “Throttle Position” is stable and that stable.
the engine is able to reach high idle speed. Refer to Troubleshoot-
ing, “Speed Control - Test”. Repair :Make the necessary repairs. Refer to Trou-
bleshooting, “Speed Control - Test”.
5. Check that the Fuel System is Operation Properly Cylinder cutout test Result : The “Cylinder Cutout Test” was successful.
A. Start the engine. Proceed to Test Step 6.
B. Access the Cylinder Cutout Test in the Diagnostic Tests under Result : The “Cylinder Cutout Test” was not
the “Diagnostics” menu. successful.
C. Select the “Automatic Cylinder Cutout Test” on the electronic Repair : Repair the cylinders that failed the “Cylinder
service tool. Cutout Test” . Reset all active codes and clear all
logged codes. Verify that the repair has eliminated the
D. Start the test. problem in the cylinder.
(continued)
UENR4542-04 123
(Table 67, contd)

6. Check the Fuel Supply Pressure Fuel supply Result : The fuel supply is stable.
pressure
A. Check the fuel pressure. Ensure that the fuel is stable. Refer to Proceed to Test Step 7.
Systems Operation/Testing and Adjusting for the procedure to
check the fuel pressure manually. Result : The fuel supply is not stable.
B. Visually check the fuel level. Do not rely on the fuel gauge only. Repair : Make the necessary repairs. Verify that the
If necessary, add fuel. If the engine has been run out of fuel, purge repair eliminates the problem.
the air from the fuel system.
C. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position.
D. Check the fuel lines for the following problems:
· Restrictions
· Collapsed lines
· Pinched lines
· Loose connections
E. Prime the fuel system if any of the following procedures have

been performed:
· Replacement of the fuel filters

· Service on the low-pressure fuel supply circuit
· Replacement of unit injectors
F. Check the fuel tank for foreign objects which may block the fuel
supply.
G. Check the fuel filters.
H. Check the fuel quality. Make sure that the fuel meets the re-
quirements in the Operation and Maintenance Manual.
Note : Cold weather adversely affects the characteristics of the

fuel. Refer to the Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-weath-
er operation.
7. Check for Restriction in the Air Inlet and Exhaust System Restrictions Result : There are restrictions in the air inlet or ex-
haust system.
A. Ensure that the turbocharger or turbochargers are operating
correctly. Periodic inspection and cleaning are recommended for Repair : Repair the restrictions or remove the
the turbocharger compressor housing or housings (inlet side). restrictions.
B. Check the air filter restriction indicator. Clean plugged air filters
or replace plugged air filters.
C. Check the air inlet and exhaust system for restrictions and/or
leaks.
124 UENR4542-04
i06262532
Valve Lash Is Excessive
Probable Causes
• Valve lash setting is not at factory specifications.
• Worn rocker arms

• Worn valve springs or broken valve springs
• Bent pushrods
• Worn camshaft
• Valve seat wear
Recommended Actions
Table 68
1. Valve Lash Setting Valve lash Result: The valve lash is set to specifications.
A. Check the engine valve lash. If necessary, adjust the engine Return the unit to service.
valve lash. Refer to Systems Operation/Testing and Adjusting
for information on adjusting the engine valve lash. Result: The valve lash cannot be set to specifications.
2. Rocker Arms Rocker arms Result: The rocker arms are damaged.
A. Inspect rocker arms for pitting or spalling on the roller. Repair: Replace parts, if necessary. If the symptom remains,
proceed to Test Step 3.
B. Check the rocker arm for a missing button.
If the problem has been corrected, return the unit to service.
Result: The rocker arms are not damaged.
3. Valve Springs Valve springs Result: The valve springs are not broken or cracked.
A. Check for cracked valve springs or broken valve springs. Proceed to Test Step 4.
Result: The valve springs are broken or cracked.
Repair: Replace parts, if necessary. If the symptom remains,

(continued)
UENR4542-04 125
(Table 68, contd)
4. Pushrods Pushrods Result: The pushrods are not worn or bent.
A. Check the pushrods for wear and straightness. Proceed to Test Step 5.
B. Roll the pushrods on a flat surface in order to determine the Result: The pushrods are worn or bent.
straightness of the rod.
Repair: Replace parts, if necessary. If the symptom remains,
5. Camshaft Camshaft Result: The camshaft measured within specifications.
A. Remove the camshaft in order to inspect the camshaft. Proceed to Test Step 6.
B. Inspect the camshaft for large grooves. Result: The camshaft did not measure within specifications.
C. Measure the camshaft in order to determine if the camshaft Repair: Make the necessary repairs, If the symptom remains,
is in specifications. Refer to Specifications, “Camshaft” for the proceed to Test Step 6. If you replace the camshaft, replace
correct measurements. the valve lifters.
6. Cylinder Head Engine Result There are worn or damaged engine components.
components
A. Remove the cylinder head. Refer to the Reuse and Salvage Repair: Replace parts, if necessary.
Guidelines for the reusability specifications.
B. Inspect the piston and valve for damage.
C. Inspect the valve seat for wear.

steps are listed.
i06262547
Valve Rotator or Spring Lock

Is Free
Use this procedure in order to troubleshoot a problem

with the valve rotators or spring locks.
Probable Cause
• Valve Components
126 UENR4542-04
Recommended Actions
Table 69
1. Valve Components Damaged Result: The valve components are damaged.

components
A. Inspect the following components for damage: Repair: Replace the damaged components.
1. Valve rotators A valve rotator that is cracked or a valve rotator that is

2. Spring locks broken is an indication of an engine overspeed. Deter-
3. Valve springs mine the cause of the engine overspeed. Repair the
4. Valves condition.
B. Ensure that the valve has not contacted the piston. If the
valve has contacted the piston, check the exhaust system for
debris.

steps are listed.
UENR4542-04 127
Circuit Tests
Circuit Tests
i06618882
Air Shutoff - Test
This procedure checks the circuits for the air shutoff

system. The Electronic Control Module (ECM) does
not provide diagnostics for the air shutoff system
circuits.
There are two conditions which can cause the ECM
to activate the air shutoff:
Engine Overspeed – The first condition occurs when
the ECM detects an engine overspeed condition. The
ECM energizes the air shutoff solenoid and the fuel
injection is disabled. The air shutoff system is latched
by the ECM until the keyswitch is cycled.
System Test – The second condition occurs when a

test of the air shutoff is performed. The overspeed
verify switch can be activated by the operator in to
perform this test. The engine speed is then increased
to 75 percent of the programmed overspeed setpoint.
The ECM activates the air shutoff system as the
engine speed exceeds 75 percent of the
programmed overspeed setpoint. The ECM
energizes the air shutoff solenoid and fuel injection is
disabled. The air shutoff system is latched by the
ECM until the keyswitch is cycled.
Note: If the “Air Shutoff” is set to “Not Installed” , the

functionality for the overspeedverifyswitch remains
operational. If the switch is activated during engine
operation, the ECM will disable injection for any
engine speed over 75 percent of the programmed
overspeed setpoint. As the engine speed drops
below 75 percent of the programmed overspeed
setpoint, the injection is enabled by the ECM. This
functionality is not latched by the ECM and the
functionality is disabled when the switch is turned off.
For some air shutoff systems, after the air shutoff
mechanism has been tripped, a manual reset of the
mechanism may be necessary.
128 UENR4542-04
Circuit Tests
Schematic for the air shutoff system

ECM connectors (typical example) Customer connector (typical example)
(1) J1/1 ECM connectors (2) J61 customer connector
UENR4542-04 129
Circuit Tests
Air shutoff mechanism
(3) Terminals for the air shutoff solenoid
Terminal locations at the P61 customer connector
that are associated with the air shutoff system
(4) Air shutoff relay
(5) Return
(40) Overspeed verify switch
130 UENR4542-04
Circuit Tests
Table 70
1. Inspect the Electrical Connectors and

the Wiring Electrical Connectors and Wiring Result: The electrical connectors and wiring
are OK.
A. Remove electrical power from the ECM.
B. Verify that the air shutoff mechanisms are
set to the OPEN position. Result: The electrical connectors are NOT
OK.
C. Thoroughly inspect connectors (1) and (2).
Also, inspect connections (3) at the air shutoff Repair: Repair or replace the damaged parts
solenoid. Refer to Troubleshooting, “Electrical and return to service.
Connectors - Inspect” for more information.
D. Perform a 45 N (10 lb) pull test on each of

the wires that are associated with the circuit for
the air shutoff system. Perform a 45 N (10 lb)
pull test on each of the wires that are associ-
ated with the circuit for the air shutoff system.
E. Check the allen head screw on each ECM

connector for the proper torque. Also, check
the allen head screw on the customer connec-
tor for the proper torque. Refer to Trouble-
shooting, “Electrical Connectors - Inspect” for
the correct torque values.
F. Check the harness and the wiring for abra-

sion and for pinch points from the air shutoff
solenoid to the ECM.
Location of the test lamp
UENR4542-04 131
Circuit Tests
Table 71
Troubleshooting Test Steps Values Results:
2. Test the Operation of the Control Sole- Control Solenoid Results: The test lamp illuminated. The air
noid for the Air Shutoff Relay shutoff relay is operating correctly. Proceed to
Test Step 3.
A. Turn the keyswitch to the OFF position.
Results: The test lamp did not illuminate. No
B. Remove the wire from the output of the air voltage is present at the output of the relay.
shutoff relay. Proceed to Test Step 4.
C. Connect a test lamp between the output of

the solenoid for the air shutoff relay and engine
ground.
D. Start the engine.
E. Activate the overspeed verify switch.
F. Monitor the test lamp whilst you increase the

engine speed past 75 percent of the pro-
grammed overspeed setpoint.
G. Stop the engine.
H. Remove the test lamp from the circuit. Re-

store the wiring to the original configuration.
(continued)
132 UENR4542-04
Circuit Tests
(Table 71, contd)
3. Test for Voltage at the Air Shutoff Voltage Results: The test lamp illuminated.
Solenoid
Repair: The voltage is present at the air shut-
A. Ensure that the keyswitch is in the OFF off solenoid. Check for continuity of the ground
position. circuit for the air shutoff solenoid before pro-
ceeding. If the ground circuit is OK, replace the
B. Disconnect the wire from the positive termi- air shutoff solenoid. Verify that the problem is
nal of the air shutoff solenoid. resolved.
C. Connect a test lamp between the wire for STOP

the positive terminal of the air shutoff relay and
engine ground. Results: The test lamp did not illuminate.
D. Start the engine. Repair: System voltage was not present at the
air shutoff solenoid. There is a problem in the
E. Activate the overspeed verify switch. wiring between the output of the air shutoff re-
lay and the input of the air shutoff solenoid.
F. Monitor the test lamp whilst you increase the There may be a problem in a connector. Re-
engine speed past 75 percent of the pro- pair the wiring and/or the connector. Replace
grammed overspeed setpoint. parts, if necessary. Verify that the problem is
resolved.
G. Stop the engine.
STOP
4. Test the Control Input Voltage at the Air Input Voltage Results: The test lamp illuminated. Control in-
Shutoff Relay put voltage is reaching the relay. Proceed to
Test Step 6.
A. Ensure that the keyswitch is in the OFF
position. Results: The test lamp did not illuminate.
B. Disconnect the wires from the control input Repair: The voltage from the ECM was not
of the air shutoff relay at the relay. present at the coil of the air shutoff relay. Re-
store the wiring to the original configuration.
C. Connect the test lamp between the two con- Proceed to Test Step 5.
trol wires.
D. Start the engine.
E. Activate the overspeed verify switch.
F. Monitor the test lamp whilst you increase the

engine speed past 75 percent of the pro-
G. Stop the engine.

UENR4542-04 133
Circuit Tests
Table 72
5. Check the Output Voltage for the Air Output Voltage Results: The test lamp illuminated.
Shutoff Relay at the ECM
Repair: The ECM is operating correctly. Per-
A. Ensure that the keyswitch is in the OFF form the following procedure:
position.
1. Verify the continuity of the ground circuit for
B. Disconnect the P1 ECM connector. the overspeed verify switch.
C. Fabricate a jumper wire that is long enough 2. Isolate the overspeed verify switch from the
to reach from the P1-54 ECM connector to en- circuit. Close the switch and measure the con-
gine ground. Crimp a connector socket to one tinuity across the switch. Open the switch and
end of the jumper wire. measure the continuity across the switch.
D. Remove the wire from terminal location P1- 3. Verify the continuity of the circuit between
54 (overspeed verify switch) at the ECM con- the overspeed verify switch and the P1 ECM
nector. Insert the jumper wire into this terminal connector.
location.
4. Restore the wiring to the original
E. Fabricate two other jumper wires that can configuration.
be used as test leads at the ECM connector.
Crimp a connector socket to one end of each If the overspeed verifyswitch is OK and the
jumper wire. circuit has continuity from the P1 and the
engine ground stud, there is a problem in
F. Remove the wires from terminal locations the wiring between the P1 ECM connector
P1-11 (air shutoff solenoid) and P1-67 (sole- and the air shutoff relay. Repair the circuit
noid return) at the ECM connector. Insert one connectors or wiring and/or replace the circuit
of the jumper wires into each of these terminal connectors or wiring. Verify that the problem is
locations. resolved.
G. Connect the J1/P1 ECM connectors. STOP

Results: The test lamp did not illuminate.
H. Connect the loose end of the jumper wire
that is in terminal location P1-54 to the engine Repair: Restore the wiring to the original con-
ground stud. figuration. There is a problem with the ECM.
Replace the ECM. Refer to Troubleshooting,
I. Connect the leads of the voltage test lamp to “ECM - Replace”.
the loose ends of the other two jumper wires
that are in the P1 ECM connector. STOP
J. Start the engine.
K. Monitor the test lamp whilst you increase

the engine speed past 75 percent of the pro-
L. Stop the engine.
Diode leads
134 UENR4542-04
Circuit Tests
Table 73
6. Test the Diode for the Control Circuit Diode Results: The voltage drop across the diode is
less than 1 V. The voltage drop across the di-
A. Disconnect the air shutoff relay control ode is OK. Proceed to Test Step 7.
wires at the relay.
Results: The voltage drop across the diode is
B. Remove the diode from the air shutoff relay. greater than 1 V.
C. Select the “Diode Check” function on a digi- Repair: The diode is damaged. Replace the
tal voltmeter. diode. Verify that the problem is resolved.
D. Place the red lead of the digital voltmeter on STOP

the diode at location (A). Place the black lead
of the digital voltmeter on the diode at location
(B).
E. Measure the voltage drop across the diode.
7. Test the Diode for Current Flow Current Flow Results: The digital voltmeter indicates an OL
across the diode for this measurement. The di-
A. Reverse the position of the leads for the dig- ode is OK. Proceed to Test Step 8.
ital voltmeter.
Results: The digital voltmeter does not indi-
B. Measure the voltage drop across the diode. cate an OL across the diode.
Repair: The diode is damaged. Replace the

diode. Verify that the problem is resolved.
STOP
Location of the test lamp
UENR4542-04 135
Circuit Tests
Table 74
8. Check the Voltage from the Keyswitch to Voltage Results: The test lamp illuminated.
the Voltage Input of the Air Shutoff Relay
Repair: The relay contacts are not passing the
A. Ensure that the keyswitch is in the OFF secondary voltage to the circuit for the air shut-
position. off solenoid. Replace the air shutoff relay. Veri-
fy that the problem is resolved.
B. Remove the wire at the voltage input of the
air shutoff relay. Results: The test lamp did not illuminate. Input
voltage is not reaching the relay. Proceed to
C. Connect the test lamp between the wire for Test Step 9.
the voltage input and the terminal for the volt-
age input at the air shutoff relay.
D. Turn the keyswitch to the ON position.
E. Check the test lamp.
F. Turn the keyswitch to the OFF position.
9. Check the Harness between the Key- Wiring Harness Results: Voltage is present on terminal B and
switch and the Air Shutoff Relay terminal R at the keyswitch.
A. Turn the keyswitch to the OFF position. Repair: If voltage is present on terminal R, re-
pair the wire between the keyswitch and the air
B. Remove the wire from terminal R (key- shutoff relay. Verify that the breaker is not
switch) of the keyswitch. tripped. Return all wiring to the original config-
uration. Verify that the problem is eliminated.
C. Turn the keyswitch to the ON position.
STOP
D. Measure the voltage between terminal B
(+Battery) of the keyswitch and engine ground. Results: Voltage is not present on terminal B
at the keyswitch.
E. Measure the voltage between terminal R
(keyswitch) of the keyswitch and engine Repair: If voltage is not present on terminal B,
ground. repair the wire between the +Battery and the
keyswitch. Verify that the breaker is not
F. Turn the keyswitch to the OFF position. tripped. Verify that the battery disconnect
switch is operating correctly. Check the battery
no-load voltage. Return all wiring to the origi-
nal configuration. Verify that the problem is
eliminated.
Results: Voltage is not present on terminal R

at the keyswitch.
Repair: If voltage is present on terminal B of

the keyswitch but not present on terminal R,
replace the keyswitch. Return all wiring to the
original configuration. Verify that the problem
is eliminated.
STOP
136 UENR4542-04
Circuit Tests
i06619530
CAN Data Link - Test
The CAN data link is used to communicate

information between the Electronic Control Module
(ECM) and other modules. Use this procedure to
troubleshoot any suspect problems with the CAN
data link. Also use this procedure if the following
diagnostic code is active or recently logged:
Table 75

639–9 247-9 SAE J1939 Data Link : Abnormal Update Communication has been lost to one or more of the devices
Rate on the datalink. If multiple devices are not communicating,
there is likely a problem with the data link wiring, power, or
ground circuits.
This procedure identifies the following problems:

• Faulty connectors
• Missing termination resistors

• Short circuits
• Open circuits
• Faulty J1939 display
Schematic for the CAN data link
UENR4542-04 137
Circuit Tests
Engine view (typical example)
(1) J1/P1 ECM connectors
P1 terminals that are associated with the CAN data
link
(P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +
Engine view (typical example)
(2) J61 customer connector
(3) J63 service tool connector
138 UENR4542-04
Circuit Tests
J61/P61 terminals that are associated with the CAN
data link
(16) CAN shield
(17) CAN data link +
(18) CAN data link −
UENR4542-04 139
Circuit Tests
Table 76
1. Inspect the Electrical Connectors and the Wiring Connectors and Wiring Results: The harness and the wiring appear to
be OK. Proceed to Test Step 2.
Results: There is a problem in the wiring
B. Thoroughly inspect connectors (1), (2), and (3). Thoroughly harness.
inspect the connectors for each module that is connected to
the CAN data link. Refer to Troubleshooting, “Electrical Con- Repair: Repair the connectors and/or the wir-
nectors - Inspect”. ing. Replace parts, if necessary. Ensure that all
the seals are properly in place and ensure that
C. Perform a 45 N (10 lb) pull test on each of the wires that are the connectors are coupled. Verify that the
associated with the CAN data link. problem is resolved.
D. Check the allen head screw on each ECM connector for the STOP
proper torque. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect” for the correct torque value.
E. Check the allen head screw on the customer connector for

the proper torque. Refer to Troubleshooting, “Electrical Con-
nectors - Inspect” for the correct torque value.
F. Check the wiring harnesses for abrasion, for corrosion and

for pinch points.
2. Check for Codes Codes Results: No codes are active.
A. Connect the electronic service tool to the service tool Repair: The problem may be intermittent. If the
connector. problem is intermittent, refer to Troubleshoot-
ing, “Electrical Connectors - Inspect”.
B. Turn the keyswitch to the ON position.
STOP
C. Observe the active diagnostic code screen on the electronic
service tool. Wait at least 15 seconds so that any diagnostic Results: A 247-9 diagnostic code is active.
codes may become active. Check for a 247-9 diagnostic code. Proceed to Test Step 3.
(continued)
140 UENR4542-04
Circuit Tests
(Table 76, contd)
3. Verify the Proper Installation of the CAN Data Link CAN Data Link Results: The resistance is between 57 and 63
Ohms. Proceed to Test Step 6.
A. Disconnect the J1939 display.
Results: The resistance is between 114 Ohms
B. Disconnect the P1 connector and measure the resistance and 126 Ohms. A terminating resistor is
between terminals P1-50 (CAN data link +) and P1-34 (CAN missing.
data link -).
Repair: Verify that two terminating resistors ex-
ist on the data link. One resistor must be on
each end of the data link. If the optional har-
ness is ordered with the engine, the engine is
shipped with one terminating resistor that is in-
stalled between the ECM and the customer
connector. Refer to the appropriate electrical
schematic to determine the missing resistor.
Replace the missing resistor. Verify that the
problem is resolved.
STOP
Results: The resistance is less than 57 Ohms.

Results: The resistance is greater than 126

Ohms. Proceed to Test Step 5.
4. Check for a Short Circuit Short Circuit Results: Each check of the resistance indi-
A. Disconnect the J1/P1 ECM connector. cates an open circuit. Proceed to Test Step 5.
B. Remove the terminating resistors from the CAN data link.
C. If a J1939 display is installed, disconnect the display. Results: At least one check of the resistance
D. Measure the resistance between the points that are listed in does not indicate an open circuit. There is a
Table 2. Be sure to wiggle the wires in the harnesses as you short circuit in a harness. There may be a prob-
make each resistance measurement. lem with a connector.
Repair: Repair the wiring and/or the connector.

Replace part, if necessary. Verify that the prob-
lem is resolved.
STOP
Table 77
Resistance Measurements for the CAN Data Link
Connector and Terminal Terminal
All the other terminals on the P1
P1-50 (CAN data link +) connector
Engine ground

P1-34 (CAN data link -) connector
Engine ground
UENR4542-04 141
Circuit Tests
Table 78
5. Check for an Open Circuit 10 Ohms Results: The resistance is less than 10 Ohms.
There is not an open circuit. Proceed to Test
A. Verify that all the connections are Step 6.
disconnected.
Results: The resistance is more than 10
B. Fabricate a jumper wire. Use the jumper Ohms. There is an open circuit or excessive
wire to create a short circuit between terminals resistance in the circuit. There may be a prob-
G and F on the service tool connector. lem in a connector.
C. Measure the resistance between terminals Repair: Repair the wiring and/or the connec-
P1-50 (CAN data link +) and P1-34 (CAN data tor. Replace part, if necessary. Verify that the
link -). problem is resolved.
D. Remove the jumper wire from the service STOP

tool connector.
6. Check the J1939 Display J1939 Display Results: The J1939 display operates properly
on another engine.
A. Connect the J1939 display to another
engine. Repair: Connect the display to the original en-
gine. If the display operates correctly, there
B. Operate the engine and monitor the J1939 may be a problem with an electrical connector.
display. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”. If the display does not operate
correctly on the original engine, there may be
a problem with the ECM.It is unlikely that the
ECM has failed. Perform this entire procedure
again. Replace the ECM if the display does not
operate correctly. Refer to Troubleshooting,
“ECM - Replace”.
Results: The J1939 display does not operate

properly on another engine.
Repair: Replace the J1939 display. Verify that

the problem is resolved.
STOP
i06619571 When the sensor is immersed in coolant, an internal

switch is closed. When the internal switch closes, the
signal for the engine coolant level is grounded
Coolant Level - Test through the sensor return. The Electronic Control
Module (ECM) detects the ground on the input for the
engine coolant level. If the signal is not present, an
event code is generated.
Use this procedure to troubleshoot any suspect Verify that the coolant level has been programmed to
problems with the engine coolant level sensor. “Enabled” on the configuration screen on the
The engine coolant level sensor provides a means of electronic service tool. If the coolant level is not
programmed, the electronic service tool will display
monitoring the engine coolant level to warn the
“Unavailable” for the parameter.
operator when the coolant level is low. The engine
coolant level sensor is located in the top tank of the
radiator. The sensor should always be immersed in
coolant.
142 UENR4542-04
Circuit Tests
Schematic of the engine coolant level sensor
Rear view of a typical radiator with an engine coolant
level sensor
Engine components for the engine coolant level
sensor
(1) P61 customer connector
(2) J1/P1 connectors
UENR4542-04 143
Circuit Tests
J61 and P61 terminals that are associated with the
engine coolant level sensor
(8) +8 VDC (digital sensor supply)
(15) Return
(36) Engine coolant level
P1 terminals that are associated with the engine
coolant level sensor
Pressurized System: Hot coolant can cause seri-
(P1-5) Return
(P1-4) +8 VDC (digital sensor supply)
ous burns. To open the cooling system filler cap,
(P1-49) Engine coolant level stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
144 UENR4542-04
Circuit Tests
Table 79
1. Check the Coolant Level Coolant Results: The coolant level is low.
A. Stop the engine. Allow the engine to cool. Repair: Add coolant according to the proce-
dure in the Operation and Maintenance Man-
B. Check the coolant level. Refer to the engine ual. Identify the source of the coolant leak and
Operation and Maintenance Manual for the fix the problem. Verify that the original problem
proper procedure. is resolved. Air may be trapped in the cooling
system. Purge any air that is trapped in the
cooling system.
STOP
Results: The coolant is at the proper level.

2. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The connectors and wiring are OK.
the Wiring Proceed to Test Step 3.
A.Turn the keyswitch to the OFF position. Results: There is a problem with the connec-
tors and/or the wiring.
B. Thoroughly inspect connectors (1) and (2).
Inspect the J800/P800 connectors for the en- Repair: Repair the wiring and/or the connec-
gine coolant level sensor. Refer to Trouble- tors. Replace parts, if necessary. Ensure that
shooting, “Electrical Connectors - Inspect”. all the seals are properly connected. Verify that
the original problem is resolved.
C. Perform a 45 N (10 lb) pull test on each of
the wires in the ECM connector, the customer STOP
connector, and the sensor connector that is as-
sociated with the circuit for the engine coolant
level sensor.
D. Check the allen head screw on each ECM

connector for the proper torque. Refer to Trou-
bleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
E. Check the allen head screw on the custom-

er connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - In-
spect” for the correct torque values.
(continued)
UENR4542-04 145
Circuit Tests
(Table 79, contd)
3. Short the Harness and Monitor the Status Coolant Level Results: The status of the “Coolant Level” is
of the “ Coolant Level”” “OK” when the jumper wire is installed. The
A. Connect the electronic service tool to the ECM, the signal wire, and the return wire are
service tool connector. OK. Proceed to Test Step 4.
B. Disconnect the J800/P800 connectors for Results: The status of the “Coolant Level” is
the engine coolant level sensor. not “OK” when the jumper wire is installed.
C. Install a jumper wire between P800-B (Digi-
tal Sensor Return) and P800-C (Coolant Level
Sensor).
D. Turn the keyswitch to the ON position.
E. Monitor the status of “Coolant Level” on the

electronic service tool whilst the jumper wire is
installed.
G. Remove the jumper wire.
H. Connect the J800/P800 connectors.
4. Check the Supply Voltage at the Sensor 8.0 ± 0.4 VDC Results: The supply voltage is reaching the
Connector sensor.
A. Disconnect the J800/P800 connectors. Repair: Replace the engine coolant level sen-
sor. Verify that the original problem is resolved.
B. Turn the keyswitch to the ON position.
STOP
C. Measure the voltage between terminals
P800-A (+8 VDC digital sensor supply) and Results: The supply voltage is not reaching
P800-B (Return) at the harness connector for the sensor.
the engine coolant level sensor.
Repair: Refer to Troubleshooting, “Sensor
D. Turn the keyswitch to the OFF position. Supply - Test (8V Supply)”, for the appropriate
troubleshooting procedure.
STOP
5. Create a Short Circuit at the ECM P1 Short Circuit Results: The status of the switch is “OK” when
Connector the jumper wire is connected. The status of the
switch is “Low” when the jumper wire is not
A. Remove terminals P1-3 and P1-49. Install a connected. The ECM is properly reading the
jumper wire into open terminals P1-3 and P1- switch input. However, the ECM did not detect
49. the jumper wire at the sensor connector. There
is a problem with the wiring. There may be a
B. Turn the keyswitch to the ON position and problem with a connector.
monitor the status of “Coolant Level” on the
electronic service tool whilst the jumper wire is Repair: Repair the wiring and/or the connec-
installed. tor. Replace parts, if necessary. Verify that the
original problem is resolved.
C. Remove the jumper wire. Monitor the status
of “Coolant Level” on the electronic service STOP
tool.
Results:The ECM is not reading the switch
D. Turn the keyswitch to the OFF position. input.
(continued)
146 UENR4542-04
Circuit Tests
(Table 79, contd)

Repair: Replace the ECM. Refer to Trouble-
shooting, “ECM - Replace”. Verify that the orig-
inal problem is resolved.
STOP
i06638115
Cooling Fan Speed - Test
Use this procedure to troubleshoot the electrical

system if a problem is suspected with the cooling fan
speed sensor. Also use this procedure if a diagnostic
code in Table 80 is active or easily repeated.
Table 80
Diagnostic trouble Codes
1639–3 544–3 Engine Cooling Fan Speed Sensor : Voltage Above Normal The code is logged.
Engine Cooling Fan Speed Sensor : Abnormal Frequency, Pulse

1639–8 544–8 The code is logged.
Width, or Period
- E662 (1) High Engine Cooling Fan Speed The code is logged.
The code is logged.

- E662 (3) High Engine Cooling Fan Speed
The engine will be shut down.
The engine cooling fan speed sensor provides a

signal to the Electronic Control Module (ECM). The
ECM controls fan speed by varying the current to the
fan control solenoid.
The engine cooling fan speed sensor receives a
supply voltage of 5.0 ± 0.2 VDC from the ECM. The
sensor outputs a frequency that is directly
proportional to fan speed. The sensor generates a
signal pulse for each revolution of the fan. The output
frequency varies between 5 Hz to 180 Hz over the
speed range between 50 rpm and 1800 rpm.
Schematic for the fan speed sensor
UENR4542-04 147
Circuit Tests
Table 81
Required Tools
Tool Part Number Part Description Qty
A T402260 Tachometer 1
Table 82
1. Check for Active Diagnostic Codes Diagnostic codes Result: An E662 (1) or 544 diagnostic code is active.
A. Connect to the electronic service tool. Proceed to Test Step 2.
B. Check for active diagnostic codes. Result: An E662 (3) is active.
Repair: Replace the fan drive assembly.

Perform the “High Fan Speed Hours Reset” in the
“Service” menu on the electronic service tool.
Proceed to Test Step 2 to check the operation of the

new fan drive assembly.
2. Check the Status of the Engine Fan Speed Within ± 50 rpm Result: The engine fan speed is within ± 50 rpm.
A.Turn the keyswitch to the OFF position. The sensor is operating correctly. There may be an in-
termittent electrical problem in a connector or in the har-
B. Connect the electronic service tool to the service tool ness. If an intermittent problem is suspected, refer to
connector. Troubleshooting, Electrical Connectors - Inspect.
C. Turn the keyswitch to the ON position. Results: The engine fan speed is not within ± 50 rpm.
D. Access the “Fan Override Test” under the “Diagnos- Proceed to Test Step 3.
tics” menu on the electronic service tool.
E. Start the “Fan Override Test” on the electronic service

tool. Set the fan speed to 500 rpm.
F. Use Tooling (A) to determine the actual speed of the

fan.
G. Compare the engine fan speed that is reported by

the electronic service tool to the actual engine fan speed
that is reported by the photo-tachometer.
H. Deactivate the “Fan Override Test” .
I. Turn the keyswitch to the OFF position.
(continued)
148 UENR4542-04
Circuit Tests
(Table 82, contd)
3. Check the Sensor Supply Voltage at the Sensor 5.0 ± 0.2 V Result: The supply voltage is not reaching the sensor.
Connector The fault is in the wiring between the cooling fan speed
A. Turn the keyswitch to the OFF position. sensor and the ECM.
B. Disconnect the sensor connector from the wiring Repair: Repair the faulty wiring or replace the faulty
harness. wiring.
C. Turn the keyswitch to the ON position. Results: The supply voltage is reaching the sensor.
D. Measure the sensor supply voltage between terminal Proceed to Test Step 4.
2 and terminal 5 on the harness connector for the
sensor.
4. Check the Signal Frequency at the Sensor Approximately 80 Hz Results: The frequency is approximately 80 Hz. The
Connector engine cooling fan speed sensor is generating the cor-
rect signal.
Repair: Repair the harness or replace the harness.
B. Remove the wire from terminal 1 on the sensor side
of the connector. Connect the sensor connector. STOP
C. Turn the keyswitch to the ON position. Results: The frequency is not approximately 80 Hz.
D. Access the “Fan Override Test” under the “Diagnos- Repair: Replace the fan drive assembly.
tics” menu on the electronic service tool. Verify that the problem is resolved.
E. Start the “Fan Override Test” on the electronic service STOP

tool. Set the fan speed to 800 rpm.
F. Use a multimeter to measure the frequency between

the signal wire from the sensor and engine ground.
G. Deactivate the “Fan Override Test” .
H. Turn the keyswitch to the OFF position.
I. Restore all connectors and wiring to the original

configuration.
i06619581 The Perkins Data Link is the standard data link that is
used by the ECM to communicate with the electronic
Data Link - Test service tool. The ECM communicates with the
electronic service tool to share status information and
diagnostic information. The electronic service tool
can also be used to configure the ECM parameters.
This information will not be available if
Note: This procedure checks for an open circuit or for communication fails between the ECM and the
a short circuit in the Perkins Data Link. If you are electronic service tool.
experiencing problems with communications
between the electronic service tool and the Electronic
Control Module (ECM), refer to troubleshooting
without a diagnostic code Troubleshooting,
“Electronic Service Tool Will Not Communicate with
ECM” before you use this procedure.
UENR4542-04 149
Circuit Tests
Schematic for the Perkins Data Link

Typical engine view Typical engine view
(1) J1/P1 ECM connectors (2) P61 customer connector
(3) P63 service tool connector
150 UENR4542-04
Circuit Tests
Perkins Data Link
(6) Perkins Data Link −
(7) Perkins Data Link +
P1 terminals that are associated with the Perkins
Data Link
(P1-8) Perkins Data Link +
(P1-9) Perkins Data Link −
Table 83
1. Inspect the Electrical Connectors and the Wiring Electrical Connectors and Results: The harness and the connectors appear to
Wiring be OK. Proceed to Test Step 2.
A. Remove the electrical power from the ECM.
Results: The connectors and/or the wiring are not
B. Thoroughly inspect connectors (1), (2), and (3). Refer OK.
to Troubleshooting, “Electrical Connectors - Inspect”.
Repair: Repair the connectors and/or the wiring.
C. Perform a 45 N (10 lb) pull test on each of the wires that Replace parts, if necessary. Ensure that all the seals
are associated with the Perkins Data Link. are properly in place and ensure that the connectors
are coupled. Verify that the original problem is
D. Check the allen head screw on each ECM connector resolved.
for the proper torque. Also, check the allen head screw on
the customer connector for the proper torque. Refer to STOP
Troubleshooting, “Electrical Connectors - Inspect”, for the
correct torque values.
UENR4542-04 151
Circuit Tests
Table 84
Resistance Measurements for the Perkins Data Link
Connector and Terminal Terminal
P1-8 (Perkins Data Link +) connector
Ground stud
P1-9 (Perkins Data Link -) connector
Ground stud
Table 85
2. Check for a Short Circuit Short Circuit Results: Each check of the resistance indi-
cates an open circuit. Proceed to Test Step 3.
A. Disconnect the J1 connector.
Results: At least one check of the resistance
B. Disconnect the electronic service tool from does not indicate an open circuit. There is a
the service tool connector. short circuit in the harness or in a connector.
C. Measure the resistance between the points Repair: Repair the connectors and/or the wir-
that are listed in Table 84 . Be sure to wiggle ing. Replace parts, if necessary. Verify that the
the wires in the harnesses as you make each original problem is resolved.
resistance measurement.
STOP
3. Check for an Open Circuit 10 Ohms Results: Each check of the resistance is less
than 10 Ohms.
A. Fabricate a jumper wire. Use the jumper
wire to create a short circuit between terminals Repair: Perform the following procedure:
J63-D (Perkins Data Link +) and J63-E (Per-
kins Data Link −). 1. Connect the J1/P1 connectors. Connect the
electronic service tool to the service tool
B. Measure the resistance between P1-8 (Per- connector.
kins Data Link +) and P1-9 (Perkins Data Link
−). 2. Check the Perkins Data Link for proper op-
eration. If the Data Link does not operate cor-
rectly, there may be a problem with the ECM.
Temporarily install a new ECM. Check the Per-

kins Data Link again. If the new ECM solves
the problem, install the original ECM and verify
that the original problem returns. If the new
ECM operates correctly and the original ECM
does not operate correctly, replace the original
ECM. Verify that the problem is resolved.
STOP
Results: At least one check of the resistance

is greater than 10 Ohms. There is an open cir-
cuit or excessive resistance in the harness.
There may be a problem with a connector.
Repair: Repair the wiring and/or the connec-

tors. Replace parts, if necessary. Verify that
the original problem is resolved.
STOP
152 UENR4542-04
Circuit Tests
i06619584
Electrical Power Supply - Test
Table 86
Diagnostic Trouble Codes for the Electrical Power Supply

(Code descriptions may vary)
PDL Code Code Description

J1939 Code (code descriptions may vary) Comments
168-2 168-2 Battery Potential / Power Input #1 : Erratic, Intermittent, or Incorrect When the engine is running, the battery
voltage drops below 9 V intermittently, or
the battery voltage drops below 9 V three
times in 7 seconds.
The ECM will log the diagnostic code.
The engine may misfire and/or shutdown
168-3 168-3 Battery Potential / Power Input #1 : High - most severe (3) The Electronic Control Module (ECM)
168–0 168–0 detects the following condition:
For 12 V systems, the ECM reads bat-

tery voltage that is above 16 V.
tery voltage that is above 32 V.
168-4 168-4 Battery Potential / Power Input #1 : Low - most severe (3) The ECM has been powered for at least
168–1 168–1 3 seconds. The ECM detects the follow-
ing condition:

tery voltage that is below 9 V.
tery voltage that is below 18 V.

The engine may shut down.
The engine may have hard starting and/
or misfire.
The contacts for the starting motor sole-
noid may be chatter during cranking.
This condition can damage the contacts.
This procedure tests whether proper voltage is being The cause of an intermittent power supply to the
supplied to the Electronic Control Module (ECM). ECM can occur on either the positive side or the
negative side of the battery circuit. Both sides are
Unswitched battery voltage is supplied through the routed from the ECM to the battery. The three
customer connector to the ECM at P1-48, P1-52, P1- connections for the unswitched +Battery should be
53, and P1-55. The negative battery is supplied to the routed through a dedicated protective device (circuit
ECM at P1-61, P1-63, P1-65, and P1-69. The ECM breaker).
receives the input from the keyswitch at P1-70 when
the keyswitch is in the ON position or the START The engine ECM requires the keyswitch to be in the
position. When the ECM detects battery voltage at ON position to maintain communications with the
this input, the ECM will power up. When battery electronic service tool.
voltage is removed from this input, the ECM will
power down.
UENR4542-04 153
Circuit Tests
Schematic diagram for the electrical power supply
154 UENR4542-04
Circuit Tests

Left side view P1 terminals that are associated with the electrical
(1) P61 customer connector
power supply
(2) J1/P1 ECM connectors (P1-44) Shutdown
(P1-48) +Battery
(P1-52) +Battery
(P1-53) +Battery
(P1-55) +Battery
(P1-61) −Battery
(P1-63) −Battery
(P1-65) −Battery
(P1-69) −Battery
(P1-70) Keyswitch
UENR4542-04 155
Circuit Tests
electrical power supply
(1) +Battery
(26) Keyswitch
(27) Shutdown
(31) +Battery
(32) +Battery
156 UENR4542-04
Circuit Tests
Table 87
1. Inspect the Electrical Connectors and the Wiring Electrical Connectors and Results: The connectors and wiring are OK. Proceed
Wiring to Test Step 2.
A. Check all circuit breakers.
Results: There is a problem with the connectors or
B. Check the battery. wiring.
C. Turn the keyswitch to the OFF position. Repair: Repair the connectors or wiring and/or replace
the connectors or wiring. Ensure that all the seals are
D. Thoroughly inspect connectors (1) and (2). Inspect the properly in place and ensure that the connectors are
connections for the battery and the connections to the coupled.
keyswitch. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”, for details. STOP
E. Perform a 45 N (10 lb) pull test on each of the wires that

are associated with the electrical power supply.
F. Check the allen head screw on each ECM connector for

the proper torque. Refer to Troubleshooting, “Electrical
Connectors - Inspect”, for the correct torque values.
G. Check the harness and wiring for abrasions and for

pinch points from the battery to the ECM. Also, check the
harness and wiring for abrasions and for pinch points from
the keyswitch to the ECM.
(continued)
UENR4542-04 157
Circuit Tests
(Table 87, contd)
2. Check the Battery Voltage at the ECM The measured voltage is Results: The ECM is receiving the correct voltage.
between 11.0 V and 13.5 V
A. Disconnect the J1/P1 ECM connector. for a 12 V system and be- Repair: If an intermittent condition is suspected, refer
tween 22.0 V and 27.0 V to Troubleshooting, “Electrical Connectors - Inspect”.
B. Turn the keyswitch to the ON position. for a 24 V system.
STOP
C. Measure the voltage between P1-52 (Unswitched Posi-
tive Battery) and P1-63 (Negative Battery). Results: Battery voltage is out of range Proceed to
Test Step 3.
D. Measure the voltage between P1-48 (Unswitched Posi-
tive Battery) and P1-61 (Negative Battery). Results: Keyswitch voltage out of range
E. Measure the voltage between P1-53 (Unswitched Posi- Repair: Check the circuit protection for the circuit and
tive Battery) and P1-65 (Negative Battery). for the wiring. Trace the wiring for the keyswitch from
the ECM through the keyswitch circuit to the batteries.
F. Measure the voltage between P1-55 (Unswitched Posi- Find the problem and repair the problem. Verify that the
tive Battery) and P1-69 (Negative Battery). repairs eliminate the problem.
G. Measure the voltage between P1-70 (Keyswitch) and

P1-63 (Negative Battery).
3. Check the Batteries Minimum specification for Results: The batteries are OK.
a 12V or 24V system
A. Measure the no-load battery voltage at the battery Repair: Check the wiring between the batteries and
posts. the ECM for shorts. Check the connectors between the
batteries and the ECM for moisture and/or corrosion.
B. Load-test the batteries. Refer to Systems Operation, Repair the wiring and/or the connectors. Verify that the
Testing and Adjusting “Battery - Test”. repair eliminates the problem.
STOP
Results: The battery voltage is low or the battery did

not pass the load test.
Repair: Recharge or replace the faulty batteries. Verify

that the repair eliminates the problem.
STOP
i06622569
Ether Starting Aid - Test
Before you test the ether injection system,

remove the ether canister from the system.
Use this procedure to troubleshoot the ether system
or use this procedure if a diagnostic code in Table 88
is active or logged.
158 UENR4542-04
Circuit Tests
Table 88
Code Descriptions
Engine Start Enable Device 1 : Current The code is latched. The code is logged.
626-5 2417-5
Below Norm Ether injection is disabled.
Engine Start Enable Device 1 : Current The code is latched. The code is logged.
626-6 2417-6
Above Normal Ether injection is disabled.
Schematic of the ether injection system

Engine view (typical example) Engine view (typical example)
(1) J1/P1 ECM connectors (2) P61 customer connector
UENR4542-04 159
Circuit Tests

Ether starting aid group (typical example) P61 terminals for the ether injection system
(3) Ether injection solenoid (22) Ether injection solenoid
(38) Override switch
Terminal locations at the harness connector for the
ether solenoid
(1) Ether injection solenoid
(2) Chassis ground
P1 terminals for the ether injection system
(P1-10) Ether injection solenoid
(P1-22) Override switch
160 UENR4542-04
Circuit Tests
Table 89
1. Inspect the Electrical Connectors and the Wiring Electrical Connectors and Results: The connectors and wiring appear to be
Wiring OK. Proceed to Test Step 2.
A. Remove electrical power from the ECM.
Results: The connectors and/or wiring are not OK.
B. Thoroughly inspect connectors (1) and (2). Also, thor-
oughly inspect the connectors for solenoid (3). Refer to Repair: Repair the connectors and/or the wiring. Re-
Troubleshooting, “Electrical Connectors - Inspect”. place parts, if necessary. Verify that the problem is
resolved.
C. Perform a 45 N (10 lb) pull test on each of the wires in
the ECM connector that are associated with the ether injec- STOP
tion system.
D. Check the allen head screw on each ECM connector for

the proper torque. Also check the allen head screw on the
customer connector for the proper torque. Refer to Trouble-
shooting, “Electrical Connectors - Inspect” for the correct
torque values.
E. Check the harness and the wiring for abrasion and for
pinch points from the ether injection solenoid to the ECM.
2. Check the Ether Canister for Starting Fluid Starting Fluid Results: The ether canister is not empty. Do not in-
A. Remove electrical power from the ECM. stall the ether canister. Proceed to Test Step 3.
B. Remove the ether canister from the ether valve. Deter- Results: The ether canister is empty.
mine if the canister contains fluid.
Repair: Replace the empty ether canister with a full
ether canister. Verify that the original problem is
resolved.
STOP
3. Check for Codes Codes Results: There are no active codes.
A. Connect the electronic service tool to the service tool Repair: The problem seems to be resolved. The
connector. problem may have been caused by a poor electrical
connection. Carefully reinspect the connectors and
B. Restore electrical power to the engine ECM. the wiring. Refer to Troubleshooting, “Electrical Con-
nectors - Inspect”.
C. Proceed to the “Diagnostic Overrides” screen on the
electronic service tool. STOP
D. Activate the ether injection system. The system will acti- Results: A -5 code is currently active . The ECM is
vate for 10 seconds. detecting a low current condition in the circuit. Pro-
ceed to Test Step 5.
E. Monitor the active diagnostic code screen on the elec-
tronic service tool. Check and record any active diagnostic Results: A -6 code is currently active. The ECM is
codes. detecting excessive current in the circuit. Proceed to
Test Step 4.
F. Look for a -5 diagnostic code or a -6 diagnostic code.
G. Remove electrical power from the engine ECM.
(continued)
UENR4542-04 161
Circuit Tests
(Table 89, contd)
4. Create an Open at the Harness Connector for the Open Results: A -6 code was active before the connector
Ether Injection Solenoid was disconnected. A -5 code became active after the
connector was disconnected.
A. Disconnect the harness connector for the ether solenoid.
Repair: The circuit for the ether solenoid is OK. Tem-
B. Restore electrical power to the engine ECM. porarily connect a new solenoid to the harness, but
do not install the new solenoid. After connecting the
C. Proceed to the “Diagnostic Overrides” screen on the new solenoid to the harness, verify that there are no
electronic service tool. active codes for the ether injection system. If there
are no active codes for the ether injection system,
D. Activate the ether injection system. The system will acti- permanently install the new solenoid. Clear any
vate for 10 seconds. logged diagnostic codes.
E. Monitor the active diagnostic code screen on the elec- STOP

tronic service tool. Look for an active -5 code.
Results: A -6 code was active before the connector
Note: Wait at least 30 seconds in order for the diagnostic was disconnected. The -6 code remained active after
codes to become active. the connector was disconnected. There is a problem
in the circuit for the ether injection solenoid. There
F. Remove electrical power from the engine ECM. may be a problem with the ECM. Leave the connector
for the solenoid disconnected. Proceed to Test Step
6.
5. Create a Short at the Connector for the Ether Injec- Short Results: A -5 code was active before the jumper wire
tion Solenoid was installed. A -6 code became active after the
jumper wire was installed.
A. Disconnect the harness connector for the ether solenoid.
Repair: The engine harness and the ECM are OK.
B. Fabricate a jumper wire that is long enough to create a Temporarily connect a new solenoid to the harness,
short circuit between terminal 1 and terminal 2 at the har- but do not install the new solenoid. Verify that there
ness connector for the ether solenoid. Crimp connector pins are no active diagnostic codes for the solenoid. If
to each end of the jumper wire. there are no active diagnostic codes for the solenoid
after the installation of the new solenoid, permanently
C. Install the jumper wire between terminals 1 and 2 of the install the new solenoid. Clear any logged diagnostic
harness connector. codes.
D. Restore electrical power to the engine ECM. STOP
E. Proceed to the “Diagnostic Overrides” screen on the Results: A -5 code was active before the jumper wire
electronic service tool. was installed. The -5 code remained active after the
jumper wire was installed. Remove the jumper wire
F. Activate the ether injection system. The system will acti- and connect the connector. Proceed to Test Step 6.
vate for 10 seconds.
G. Monitor the active diagnostic code screen on the elec-

tronic service tool. Look for an active -6 code.
Note: Wait at least 30 seconds in order for the diagnostic

codes to become active.
H. Remove electrical power from the engine ECM.
I. Remove the jumper wire from the harness connector.
6. Check the Operation of the ECM ECM Results: A -5 code is active when the loose end of
the jumper wire is open. A -6 code is active when the
A. Disconnect the J1/P1 ECM connectors. loose end of the jumper wire is grounded.
(continued)
162 UENR4542-04
Circuit Tests
(Table 89, contd)

B. Fabricate a jumper wire that is long enough to create a Repair: The ECM is operating properly. The problem
test circuit from the ECM connector to the engine ground is in the circuit for the ether solenoid. The problem
stud. Crimp a connector socket to one end of the jumper may be in the harness between the ECM and the
wire. ether solenoid harness connector or the harness be-
tween the ground connection and the ether solenoid
C. Remove the wire from terminal location J1-10 (ether in- harness connector. Repair the connectors or wiring
jection solenoid) at the ECM connector. Install the jumper and/or replace the connectors or wiring.
wire into this terminal location.
STOP
D. Connect the J1/P1 ECM connectors.
Results: One of the following conditions exists: A -5
E. Check the operation of the ECM by creating an open code is not active when the loose end of the jumper
at the ECM: wire is open. A -6 code is not active when the loose
end of the jumper wire is grounded.
Note: Wait at least 30 seconds in order for the diagnostic
codes to become active. Repair: The ECM is not responding correctly. Re-
place the ECM. Refer to Troubleshooting, “ECM - Re-
F. Check the operation of the ECM by creating a short at place”. Verify that the problem is resolved.
the ECM.
G. Remove electrical power from the engine ECM.
H. Restore the wiring to the original configuration.
i06505945
Indicator Lamp - Test
The Engine Control Module (ECM) provides three

outputs that can be used to illuminate indicator
lamps. The electronic service tool can be used to
program each output to a specific J1/P1 terminal. If
applicable, some of the outputs can be programmed
to a J1939 device.
Low Side Driver – The ECM provides a connection
to ground to activate the lamp.
J1939 Device – The ECM sends digital data on the
J1939 data link to control the lamp.
Table 90 provides information on the typical lamp

outputs.
Table 90
Lamp Outputs (Typical Application)
Programming Options
Lamp Alternative
Default Output
Terminal Output Terminal
Diagnostic Lamp J1/P1:28 J1939 - Body Controller

J1939 - Cab Controller
Warning Lamp J1/P1:29 J1939 - Instrument Cluster
Maintenance Due Lamp J1/P1:30 J1939 - Cab Display
UENR4542-04 163
Circuit Tests
Special tests on the electronic service tool can

activate every lamp except the check engine lamp.
The special tests activate the lamps for all
programming options.
P1 terminals for the J1939 data link
Testing the Circuits
The ECM briefly activates the lamps when the
keyswitch is turned from OFF to ON.
164 UENR4542-04
Circuit Tests
Table 91
1. Test the Circuit Circuit test Result: The lamp does not illuminate.
A. Turn the keyswitch from OFF to ON to test the circuit. Troubleshoot any active codes before continuing with this
procedure.
B. Watch the lamp during the test.
Result: The lamp illuminates.
Repair: There is a problem with the wiring if the problem

is intermittent. Troubleshoot the wiring by referring to the
electrical schematic and Troubleshooting, “Electrical Con-
nectors - Inspect”
STOP
2. Check the Bulb Bulb Result: The lamp illuminates. The problem is resolved.
Replace the bulb with a bulb that is known to be good. Test the cir- STOP
cuit again.
Result: The lamp does not illuminate. The bulb is OK.
Repair: The +Battery or the ground is not present at the

lamp. Refer to the electrical schematic.
Troubleshoot the wiring by referring to the electrical sche-
matic if the lamp output is programmed to a J1939
device.
Proceed to Test Step 3 if the lamp output is programmed

to a J1/P1 terminal.
3. Troubleshoot the Wiring for the Lamp Lamp wiring Result: Yes - There is an open circuit in the wiring for the
lamp.
Check the wiring for an open circuit. Pay particular attention to pos-
sible problems with electrical connectors. Make the necessary repairs.
STOP
Result: No - The wiring for the lamp is OK.
4. Test the ECM Output ECM output Result: Yes - The test lamp illuminates. However, the in-
dicator lamp does not illuminate.
A. Verify that the P1 connector is connected to the ECM.
Identify the cause of the wiring problem. Make the neces-
B. Use the electronic service tool to determine the programming sary repairs.
option for the lamp output.
STOP
C. Connect a test lamp between the P1 terminal for the lamp and Result: No - The test lamp does not illuminate. There is a
terminal P1-53 (Unswitched +Battery). problem with the ECM.
D. Turn the keyswitch to the ON to test the circuit. Watch the test Replace the ECM.
lamp with the output activated.
STOP
UENR4542-04 165
Circuit Tests
i06508429
Injector Solenoid - Test
Use this procedure for the following conditions:
• A suspected problem with an injector solenoid
• You have been directed to this procedure from

Troubleshooting, “Symptom Troubleshooting”.
• There is an active diagnostic code for an injector

solenoid.
Use this procedure for the following diagnostic codes:
Table 92

Engine Injector Cylinder #01 :
651-5 1-5
Current Below Normal
Engine Injector Cylinder #02 : The Electronic Control Module (ECM) is attempting to operate the
652-5 2-5 injector. The ECM detects an open circuit in the circuit for the
injector.
653-5 3-5
Current Below Normal The ECM will log the diagnostic code.
Engine Injector Cylinder #04 : Possible performance effects:
654-5 4-5
· The engine may misfire
Engine Injector Cylinder #05 : · The engine may experience low power
655-5 5-5
656-5 6-5
651-6 1-6
Current Above Normal
Engine Injector Cylinder #02 : The Electronic Control Module (ECM) is attempting to operate the
652-6 2-6 injector. The ECM detects a short circuit in the circuit for the injector.
Engine Injector Cylinder #03 : The ECM will log the diagnostic code. The ECM will continue to at-
653-6 3-6
Current Above Normal tempt to operate the injector after the code has been logged.
Engine Injector Cylinder #04 : Possible performance effects:
654-6 4-6
· The engine may misfire
Engine Injector Cylinder #05 : · The engine may experience low power
655-6 5-6
656-6 6-6
Perform this procedure under conditions that are These engines have Electronic Unit Injectors (EUI)
identical to the conditions that exist when the that are hydraulically actuated and electronically
problem occurs. Typically, problems with the injector controlled. The Engine Control Module (ECM) sends
solenoid occur when the engine is warmed up and/or a high-voltage signal to each injector solenoid. The
when the engine is under vibration (heavy loads). signal is sent with the proper injection duration and
injection timing for the current engine load and
speed. The injector solenoid is mounted on top of the
fuel injector body.
166 UENR4542-04
Circuit Tests
If an open is detected in the solenoid circuit, a

diagnostic code is generated. The ECM continues to
try to fire the injector. If a short is detected, a
diagnostic code is generated. The ECM will disable
the solenoid circuit. The ECM will periodically try to
fire the injector. If the short circuit remains, this
sequence of events will be repeated until the problem
is corrected.
A trim file must be programmed into the ECM for
each injector. Refer to Troubleshooting, “Injector Trim
File”.
The electronic service tool includes the following
tests that aid in troubleshooting the injector
solenoids:
“ Cylinder Cutout Test””
The “Cylinder Cutout Test” is used on an engine to
determine the individual cylinder performance as the
engine is running. As one or more cylinders are cut
out during the test, the “Cylinder Cutout Test” uses
“Fuel Position” to evaluate the performance of the
cylinders that are cut out. As the different cylinders Illustration 71 g03840562
are cut out, a comparison of the change in “Fuel Electronic unit injector
Position” is used to identify cylinders that are weak or (1) Solenoid
misfiring. One reason for a cylinder that is weak or (2) Injector
misfiring is an injector that is malfunctioning.
The “Cylinder Cutout Test” can be used to isolate a
malfunctioning injector to avoid replacement of
injectors that are in good condition.
During the test, when a cylinder is cut out, an
increase in “Fuel Position” will be noticed for the
remaining cylinders. This increase in “Fuel Position”
represents an increase in the amount of fuel that
must be delivered by the remaining cylinders to
maintain the desired engine speed.
When a weak cylinder (malfunctioning injector) is cut
out, the increase in “Fuel Position” will not be as large
as the increase for a cylinder that has an acceptable
level of performance.
Note: Prior to running the “Cylinder Cutout Test” , all

active diagnostic codes must be repaired.
“ Injector Solenoid Test””
Use the “Injector Solenoid Test” to diagnose an open
circuit or a short circuit in the wiring for the injector
solenoids. With the engine stopped, the “Injector
Solenoid Test” will briefly activate each injector
solenoid. An audible click can be heard as each
solenoid is activated. After performing the test, the
electronic service tool will indicate the status of the
solenoid as “OK” , “Open” , or “Short” .
UENR4542-04 167
Circuit Tests
Schematic diagram for the injector solenoids
168 UENR4542-04
Circuit Tests
Harness connector for the injectors
Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.
P2 ECM connector
(P2-99) “Injector 5 & 6 supply”
(P2-105) “Injector 6 return”
UENR4542-04 169
Circuit Tests
Table 93
1. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The harness and wiring are OK. Pro-
the Wiring ceed to Test Step 2.
A. Turn the keyswitch to the OFF position. A Results: There is a problem in the connectors
strong electrical shock hazard is present if the and/or wiring.
keyswitch is not turned off.
Repair: Repair the connectors or wiring and/or
B. Thoroughly inspect the J2/P2 ECM connec- replace the connectors or wiring. Ensure that
tors and the valve cover injector connectors. all the seals are properly in place and ensure
Refer to Troubleshooting, “Electrical Connec- that the connectors are coupled. Verify that the
tors - Inspect”. repair eliminates the problem.
C. Perform a 45 N (10 lb) pull test on each of STOP

the wires that are associated with injector
solenoids.
D. Check the allen head screw on the ECM

connectors for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - In-
spect” for the proper torque value.
E. Check the harness and the wiring for abra-

sion and for pinch points from the valve cover
injector harness connector to the ECM.
2. Check for Codes Codes Results: No diagnostic codes for the injector
solenoids are logged. The injector solenoids
A. Establish communication between the elec- are operating correctly. There may be a me-
tronic service tool and the ECM. chanical problem with the injector fuel delivery.
Results: A diagnostic code is logged for one

or more injector solenoids. There is an electri-
cal problem with an injector solenoid or with
the circuit. Proceed to Test Step 4.
(continued)
170 UENR4542-04
Circuit Tests
(Table 93, contd)
3. Perform the “ Cylinder Cutout Test”” Cylinder Cutout Test Results: The cylinder cutout test indicates that
all the injectors are operating correctly.
A. Start the engine.
Repair: If a problem with the fuel system is
B. Allow the engine to warm to normal operat- suspected and diagnostic codes are not active
ing temperature 77 °C (171 °F). or logged, refer to Systems Operation/Testing
and Adjusting for information that is related to
C. Access the “Cylinder Cutout Test” . the low-pressure fuel system.
D. Shut off all parasitic loads such as air com- STOP

pressors which could affect the results of the
test. Results: The cylinder cutout test indicates that
at least one of the injectors is not operating
E. Follow the instructions that are given on the correctly. Proceed to Test Step 4.
screen.
F. To start the test, select the start button at the

bottom of the screen.
G. Use the electronic service tool to cut out the

cylinders to identify injectors that may have a
performance problem. Highlight a cylinder and
select the “Change” button at the bottom of the
screen. The injector for that cylinder will be dis-
abled. Check for a difference in the sound,
feel, or power of the engine. Also, look for a
change to the operating parameters that are
displayed on the “Cylinder Cutout Test”
screen.
4. Perform the “ Injector Solenoid Test”” Injector Solenoid Test Results: There is not an electronic problem
with the injectors.
A. Start the engine.
Repair: The problem appears to be resolved.
B. Allow the engine to warm to normal operat- There may be an intermittent problem in the
ing temperature 77 °C (171 °F). harness. The problem may have been caused
by a poor electrical connection in a connector.
C. Stop the engine.
If the codes continue to be logged, refer to
D. Restore the electrical power to the ECM. Troubleshooting, “Electrical Connectors -
Inspect”.
E. Access the “Injector Solenoid Test”
If the engine is misfiring or if the engine has
F. Activate the “Injector Solenoid Test” . low power, refer to Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable” or Trou-
G. As each solenoid is energized by the ECM, bleshooting, “Power Is Intermittently Low or
an audible click can be heard at the valve cov- Power Cutout Is Intermittent”.
er. Allow the “Injector Solenoid Test” to contin-
ue until each cylinder is activated at least two STOP
times.
Results: Note the cylinder that indicates
“Open” . Proceed to Test Step 5.
Results: Note the cylinder that indicates

“Short” . Proceed to Test Step 6.

UENR4542-04 171
Circuit Tests
Table 94
5. Check the Harness between the ECM and Short Results: The electronic service tool displays
the Valve Cover Base for an Open Circuit “Short” for each circuit that was jumpered. The
harness between the ECM and the valve cover
A. Remove the electrical power from the ECM. injector harness connector does not have an
open circuit. Proceed to Test Step 7.
B. Disconnect the valve cover injector harness
connector at the valve cover base. Results: The electronic service tool displays
“Open” for the cylinder with the jumper wire.
C. Restore the electrical power to the ECM. There is a problem in the wiring between the
ECM and the valve cover injector harness con-
D. Fabricate a jumper wire that will be long nector. There may be a problem with the ECM.
enough to short circuit two terminal locations Proceed to Test Step 8.
at the valve cover injector harness connector.
Crimp a connector pin to each end of the jump-
er wire.
E. Insert one end of the jumper wire into the

valve cover injector harness connector socket
for the suspect injector supply wire. Insert the
other end of the jumper wire into the valve cov-
er injector harness connector socket for the
suspect injector return wire. This action will re-
place the injector solenoid with a short circuit.
F. Perform the “Injector Solenoid Test” at least

two times.
G. Repeat this test for each suspect circuit.

Stop the “Injector Solenoid Test” before han-
dling the jumper wire.
Restore the wiring to the original configuration.

Table 95
6. Check the Harness between the ECM and Short Results: All cylinders indicate “Open” on the
the Valve Cover Base for a Short Circuit electronic service tool. The ECM and the en-
gine harness are OK. Proceed to Test Step 7.
Results: One or more cylinders indicate
B. Disconnect the valve cover injector harness “Short” on the electronic service tool. Note the
connector. cylinders that indicate “Short” . Proceed to Test
Step 8.
C. Restore the electrical power to the ECM.
D. Perform the “Injector Solenoid Test” at least

two times.
172 UENR4542-04
Circuit Tests

Table 96
7. Check the Injector Harness Under the Open Circuit or a Short Circuit Results: The electronic service tool displays
Valve Cover for an Open Circuit or a Short the correct status during the test.
Circuit
Repair: The harness wiring is OK. Replace
A. Remove the electrical power from the ECM. the faulty injector. Verify that the problem is
resolved.
B. Remove the valve cover to gain access to
the suspect injector. STOP
C. Disconnect the harness connector from the Results: The electronic service tool did not
suspect injector. display the correct status during the test.
D. Thoroughly clean the terminals on the injec- Repair: There is a problem with the injector
tor solenoid and on the harness connector. harness under the valve cover. There may be
a problem with a connector. Repair the wiring
E. Use a jumper wire to short circuit the con- and/or the connector, when possible. Replace
nector terminals for the suspect injector. This parts, if necessary.
action will replace the injector solenoid with a
short circuit. STOP
F. Restore the electrical power to the ECM.
G. Perform the “Injector Solenoid Test” at least

two times.
Note: The injector solenoid that shares the

supply wire of the injector that has a short cir-
cuit may indicate a false test result. Disregard
this test result.
H. Remove the electrical power from the ECM.
I. Remove the jumper wire from the injector

connector. This action will replace the injector
solenoid with an open circuit.
J. Restore the electrical power to the ECM.
K. Perform the “Injector Solenoid Test” at least

two times.
L. Remove the electrical power from the ECM.

UENR4542-04 173
Circuit Tests
Table 97
8. Check the ECM for Proper Operation ECM Results: The ECM detects the correct status of the
circuit.
Repair: The ECM is OK. The problem is in the engine har-
B. Fabricate a jumper that is long enough to reach from ness or in a connector. Inspect the connectors for mois-
the P2 ECM connector to the engine ground stud. Crimp a ture and for corrosion. Repair the wiring and/or the
connector socket to one end of the jumper wire. connector, when possible. Replace parts, if necessary.
Clear all diagnostic codes after you complete this test
C. Disconnect the P2 connector. step.
D. Remove the supply wire from the terminal location for STOP
the suspect injector at the ECM connector. Install the
jumper wire into this socket. Results: The ECM does not detect the correct status of
the circuit.
E. Connect the J2/P2 connectors.
Repair: There is a problem with the ECM. Replace the
F. Verify that the ECM will detect an open circuit for the ECM. Refer to Troubleshooting, “Replacing the ECM”.
suspect injector: Verify that the problem is resolved.
1. Ensure that the jumper wire is not in contact with a STOP

ground source or another circuit. Do not touch the jumper
wire during the test. A strong electrical shock hazard is
present at the jumper wire when the test is running.
2. Restore the electrical power to the ECM.
3. Perform the “Injector Solenoid Test” at least two times.
4. Remove the electrical power from the ECM.
The electronic service tool displays “ Open”” for the

two injectors that share the supply wire.
G. Verify that the ECM detects a short circuit for the sus-
pect injector:
1. Connect the jumper wire to the engine ground stud. Do

not touch the jumper wire during the test. A strong electri-
cal shock hazard is present at the jumper wire when the
test is running.
2. Restore the electrical power to the ECM.
3. Perform the “Injector Solenoid Test” at least two times.
The electronic service tool displays “ Short”” for the

two injectors that share the supply wire.
i06510367 The Electronic Control Module (ECM) provides the

PTO speed control function. The PTO speed control
Power Take-Off - Test function requires the following inputs:
• PTO switches
Use this procedure to troubleshoot any suspect • The “PTO Mode” parameter
problems with the circuits for the power take-off
controls (PTO). The PTO controls provide an The PTO switches enable the PTO speed control
alternative method of controlling the desired engine function and the PTO switches control the desired
engine speed.
speed.
174 UENR4542-04
Circuit Tests
The “PTO Mode” parameter determines the mode of

operation. There are two modes of operation: “Ramp
Up/Ramp Down” and “Set/Resume” . Use the
electronic service tool to change the value of the
parameter.
“ Ramp Up/Ramp Down”” Mode
This mode uses three inputs. The inputs are provided
by two switches.
Schematic for the PTO inputs for the “Ramp Up/Ramp Down” mode of operation
Placing the PTO Enable switch to the “Enable”

position transfers the control of the desired engine
speed from the throttle position sensor to the PTO
speed control function. The PTO Ramp Up/Down
switch controls the desired engine speed.
The PTO Ramp Up/Down switch is spring loaded to
the normally open position. When the switch is held
in the “Ramp Up” position, the desired engine speed
increases according to the value of the “Engine Accel
Rate” parameter. When the switch is released, the
desired engine speed maintains the set speed. After
the desired engine speed has been set, momentarily
placing the switch in the “Ramp Up” position
increases the desired engine speed by 20 rpm.
When the PTO Ramp Up/Down switch is held in the
“Ramp Down” position, the desired engine speed
decreases according to the value of the “Engine
Accel Rate” parameter. When the switch is released,
the desired engine speed maintains the set speed.
After the desired engine speed has been set,
momentarily placing the switch in the “Ramp Down”
position decreases the desired engine speed by 20
rpm.
If the “PTO Ramp Up” and “PTO Ramp Down” inputs
are connected to the −Battery at the same time, the
ECM will ignore the inputs. The desired engine speed
will not change.
“ Set/Resume”” Mode
This mode uses four inputs. The inputs are provided
by three switches. Refer to Illustration 76 .
UENR4542-04 175
Circuit Tests
Schematic for the PTO inputs for the “Set/Resume” mode of operation
Placing the PTO Enable switch to the “Enable”

position transfers the control of the desired engine
speed from the throttle position sensor to the PTO
speed control function. The PTO Interrupt switch
momentarily transfers control back to the throttle
position sensor. The PTO Set/Resume switch
controls the desired engine speed.
The PTO Set/Resume switch is spring loaded to the
normally open position. If the switch is momentarily
placed in the “Set” position, the desired engine speed
will be set to the current engine speed. If the switch is
held in the “Set” position, the desired engine speed
will increase according to the value of the “Engine
Accel Rate” parameter. After the desired engine
speed has been set, the desired engine speed will
increase by 20 rpm when the PTO ramp up/down
switch is momentarily placed in the “Set” position.
If the PTO Set/Resume switch is momentarily placed
in the “Resume” position, the desired engine speed
will be set to the current engine speed. If the switch is
held in the “Resume” position, the desired engine
speed will decrease according to the value of the
“Engine Accel Rate” parameter. After the desired
engine speed has been set, the desired engine
speed will decrease by 20 rpm when the switch is
momentarily placed in the “Resume” position.
If the “PTO Set” and “PTO Resume” inputs are
connected to the −Battery at the same time, the ECM
will ignore the inputs. The desired engine speed will
not change.
176 UENR4542-04
Circuit Tests

Left side view P1 terminals that are associated with the PTO
(1) P61 customer connector (P1-41) Input from the PTO interrupt switch
(1) J1/P1 ECM connectors (P1-56) Input from the PTO enable switch
(P1-58) Input from the PTO ramp up switch or set switch
(P1-60) Input for PTO ramp down switch or resume switch
UENR4542-04 177
Circuit Tests
J61/P61 terminals that are associated with the PTO
(19) Input from the PTO interrupt switch
(29) Input from the PTO enable switch
(30) Input from the PTO ramp up switch or set switch
(39) Input for PTO ramp down switch or resume switch
178 UENR4542-04
Circuit Tests
Table 98
1. Inspect the Electrical Connectors and the Electrical Connectors and Wiring Results: The connectors and wiring are
Wiring OK. If the engine is equipped with a cus-
tomer connector, proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Otherwise, proceed to Test Step 3.
B. Thoroughly inspect connectors (1) and (2). Results: There is a problem with the con-
Refer to Troubleshooting, “Electrical Connec- nectors and/or the wiring.
tors - Inspect”.
Repair: Repair the wiring and/or the con-
C. Perform a 45 N (10 lb) pull test on each of nectors. Replace parts, if necessary. En-
the wires that are associated with the circuits sure that all the seals are properly
for the PTO switches. connected. Verify that the repair eliminates
the problem.
connector for the proper torque. Refer to Trou- STOP
E. Check the allen head screw on the customer

for the correct torque value.
F. Check the harness and wiring for abrasions

and for pinch points from the battery to the
ECM.
2. Check the Inputs from the Switches at the Inputs Results: The voltage test lamp turns on
J61 Customer Connector when the switch is closed. The voltage test
lamp turns off when the switch is opened.
A. Disconnect the J61 connector. The circuit is operating correctly. Connect
the J61 connector. Proceed to Test Step 3.
B. Refer to Table 2. Connect a voltage test
lamp between the input for the suspect switch Results: The voltage test lamp does not
circuit and terminal J61-31 (+Battery). turn on when the switch is closed. Alterna-
tively, the voltage test lamp does not turn
C. Observe the voltage test lamp as you oper- off when the switch is opened. There is a
ate the suspect switch. problem with the suspect switch and/or the
wiring.
Repair: Repair the connectors or wiring

and/or replace the connectors or wiring.
Ensure that all the seals are properly in
place and ensure that the connectors are-
completely coupled. Verify that the repair
STOP
Table 99 (Table 99, contd)

J61 Terminals for the Inputs from the PTO Switches PTO ramp up switch or set
58
switch
Switch J61 Terminals
PTO ramp down switch or re-
PTO enable switch 29 60
sume switch
PTO interrupt switch 41
(continued)
UENR4542-04 179
Circuit Tests
Table 100
3. Check the Inputs from the Switches at Inputs Results: The voltage test lamp turns ON when
the J1 Connector the switch is closed. The voltage test lamp
turns OFF when the switch is opened. The
A. Disconnect the P1 connector. switch circuit is operating correctly. The prob-
lem may be in the ECM.
B. Refer to Table 4. Connect a voltage test
lamp between the input for the suspect switch Repair: An ECM failure is unlikely. Exit this
circuit and terminal J1-48 (+Battery). procedure and perform this procedure again. If
the problem is not resolved, temporarily install
C. Observe the voltage test lamp as you oper- a new ECM. Refer to Troubleshooting, “Re-
ate the suspect switch. placing the ECM”.
If the problem is resolved with the new ECM,

install the original ECM and verify that the
problem returns. IF the new ECM operates
correctly and the original ECM does not oper-
ate correctly, replace the original ECM.
STOP
Results: The voltage test lamp does not turn

on when the switch is closed. Alternatively, the
voltage test lamp does not turn off when the
switch is opened. There is a problem in the wir-
ing between the J1 connector and the switch.
There may be a problem in a connector.
Repair: Repair the wiring and/or the connec-

tor. Replace parts, if necessary. Verify that the
repair eliminates the problem.
STOP
i06622631
Retarder - Test
Use this procedure for the following diagnostic

trouble codes:
Table 101
Diagnostic Codes
1072-5 791–5 Engine (Compression) Brake Out- The code is logged.

put #1 : Current Below Normal

put #1 : Current Above Normal

put #2 : Current Below Normal

put #2 : Current Above Normal
180 UENR4542-04
Circuit Tests
Perform this procedure under conditions that are

identical to the conditions that exist when the
problem occurs. Typically, problems with the
compression brake solenoids occur when the engine
is warmed up and/or when the engine is under
vibration (heavy loads).
The compression brake uses the engine to provide
auxiliary braking for the machine. The compression
brake reduces wear of the wheel brake components,
brake oil temperature, and the chance for engine
overspeed. The compression brake also aids in the
controllability of the machine.
If the retarder is installed on the engine, the
configuration parameter for the engine retarder must
be set to “Enabled” for this function to operate. The
engine ECM will activate the appropriate
compression brake solenoids to meet the requested
level of braking.
“ Compression Brake Solenoid Override””
The Compression Brake Low/High Override and
Compression Brake Med/High Override are
diagnostic overrides that are available on the
electronic service tool. Use the overrides to help with
troubleshooting problems in the circuit for the
compression brake. The ECM will only detect shorts
in the circuit for the compression brake when the
overrides are active. The overrides must be activated
and then deactivated before the ECM will detect an
open circuit. The ECM will only detect opens in the
circuit for the compression brake when the overrides
are not active.
Note: The engine speed must be zero before the

overrides will function.
Location of the compression brake solenoid (typical
example)
UENR4542-04 181
Circuit Tests
Schematic for the compression brake circuit
182 UENR4542-04
Circuit Tests
Left side engine view (typical example)
(4) Valve cover entry connector
Left side engine view (typical example)
(2) P61 connector
UENR4542-04 183
Circuit Tests
P1 ECM connector
(P1-5) Digital return
(P1-23) Compression brake solenoid low/high
(P1-40) Compression brake med/high
P2 ECM connector
(P2-1) Compression brake solenoid low/high
(P2-8) Compression brake solenoid med/high
(P2-14) Digital return
184 UENR4542-04
Circuit Tests
P61/J61 terminals
(Terminal 9) Digital return
(Terminal 34) Compression brake solenoid low/high
(Terminal 35) Compression brake med/high
Valve cover entry connector
(10) Compression brake solenoid med/high
(11) Compression brake solenoid low/high
(12) Digital return

UENR4542-04 185
Circuit Tests
Table 102
1. Inspect the Electrical Connectors and the Wiring Electrical Connectors Result: The harness and connectors appear to be
and Wiring OK.
A.Remove electrical power from the engine ECM. A strong
electrical shock hazard is present if the electrical power is Proceed to Test Step 2.
not removed from the engine ECM.
Result: There is a problem with the connectors and/
B. Thoroughly inspect connectors (1) and (2). Refer to or wiring.
Troubleshooting, “Electrical Connectors - Inspect” for
details. Repair: Repair the connectors or wiring and/or re-
place the connectors or wiring. Ensure that all the
C. Perform a 45 N (10 lb) pull test on each of the wires in seals for each of the connectors are properly in place
the ECM connector that are associated with injector and ensure that the connectors are coupled. Verify
solenoids. that the repair eliminates the problem.
D. Check the allen head screw for each of the ECM connec- STOP
tors and the machine connectors for the proper torque. Re-
fer to Troubleshooting, “Electrical Connectors - Inspect” for
the correct torque values.
E. Check the harness and wiring for abrasion and for pinch
points from the valve cover back to the ECM.
2. Check for Active Diagnostic Codes and/or Logged Diagnostic Codes Result: No diagnostic codes are active.
Diagnostic Codes
If a problem is suspected with the “Compression
A. Connect the electronic service tool to the service tool Brake Switch” , proceed to Test Step 9.
connector.
Result: A low current diagnostic code (–5) is cur-
B. Turn the keyswitch to the ON position. rently active .
C. Access the “Special Tests” under the “Diagnostics” Proceed to Test Step 3.
menu.
Result: A high current diagnostic code (–6) is
D. Start the “Compression Brake Solenoid Test” on the logged.
E. Once the electronic service tool displays the status of the
compression brake solenoid, stop the “Compression Brake
Solenoid Test” .
F. Check for active diagnostic codes and/or logged diagnos-

tic codes that are associated with the compression brake
solenoids.
(continued)
186 UENR4542-04
Circuit Tests
(Table 102, contd)
3. Short the Wires of the Suspect Compression Brake Diagnostic Codes Result: A high current diagnostic code (–6) is
Solenoid at the Valve Cover Connector logged. The harness wiring between the valve cover
connector for the suspect compression brake sole-
A. Turn the keyswitch to the OFF position. noid and ECM connector P2 is OK.
B. Disconnect the valve cover connector for the suspect Proceed to Test Step 7.
compression brake solenoid.
Result: A low current diagnostic code (–5) is cur-
C. Fabricate a jumper wire to create a short between the rently active. The ECM did not detect the short at the
supply and the return for the suspect compression brake valve cover connector for the compression brake
solenoid. solenoid.
D. Turn the keyswitch to the ON position. Proceed to Test Step 4.
E. Access the “Special Tests” under the “Diagnostics”

menu.
F. Start the “Compression Brake Solenoid Test” on the elec-

G. Once the electronic service tool displays the status of

the compression brake solenoid, stop the “Compression
Brake Solenoid Test” .
H. Check for active diagnostic codes and/or logged diag-

nostic codes that are associated with the compression
brake solenoids.
4. Create a Short Circuit at the ECM Diagnostic Codes Note: Disconnecting the supply wire for the suspect
compression brake solenoid will cause an “Open” in
A. Turn the keyswitch to the OFF position. the compression brake solenoid that shares the sup-
ply wire with the suspect compression brake
B. Disconnect the J2/P2 ECM connector. solenoid.
C. Inspect the terminals on the J2 and P2 ECM connectors Result: A high current diagnostic code (-6) is logged.
for damage. The ECM detected the short.
Note: Refer to Illustration 84 for pin locations.
Repair: Check continuity of the supply wire for the
D. Remove the return wire and the supply wire for the sus- suspect compression brake solenoid between the
pect compression brake solenoid from the P2 ECM valve cover connector for the suspect compression
connector. brake solenoid and P2. If the wire is open, replace
the wire.
E. Fabricate a jumper wire to short the two pins for the sus-
pect compression brake solenoid at the ECM. Crimp a Check continuity of the return wire for the suspect
socket to each end of the jumper wire. Insert the jumper compression brake solenoid between the valve cov-
wire into the P2 ECM connector. er connector for the suspect compression brake sol-
enoid and P2. If the wire is open, replace the wire.
F. Reconnect the P2 ECM connector.
G. Turn the keyswitch to the ON position. STOP
H. Access the “Special Tests” under the “Diagnostics”
menu. Result: A low current diagnostic code (-5) is cur-
rently active. The ECM did not detect the short
I. Start the “Compression Brake Solenoid Test” on the elec- circuit.
Repair: Replace the ECM. Refer to Troubleshooting,
J. Once the electronic service tool displays the status of the “ECM - Replace”.
Solenoid Test” . STOP
(continued)
UENR4542-04 187
Circuit Tests
(Table 102, contd)

K. Check for active diagnostic codes and/or logged diag-
brake solenoids.
5. Open the Wires of the Suspect Compression Brake Diagnostic codes Result: low current diagnostic code (-5) is currently
Solenoid at the Valve Cover Connector active. The ECM detected the open at the valve cov-
er connector for the compression brake solenoid.
A. Turn the keyswitch to the OFF position. The harness wiring between the valve cover connec-
tor for the suspect compression brake solenoid and
B. Disconnect the valve cover connector for the suspect ECM connector P2 is OK.
compression brake solenoid.
Result: A high current diagnostic code (-6) is logged.
D. Access the “Special Tests” under the “Diagnostics” The ECM did not detect the open at the valve cover
menu. connector for the compression brake solenoid.
E. Start the “Compression Brake Solenoid Test” on the elec- Proceed to Test Step 6.
F. Once the electronic service tool displays the status of the

Solenoid Test” .
G. Check for active diagnostic codes and/or logged diag-

brake solenoids.
6. Create an Open at the ECM Diagnostic codes Result: A low current diagnostic code (-5) is cur-
rently active. The ECM detected the open at the
A. Turn the keyswitch to the OFF position. ECM.
B. Disconnect the P2 ECM connector. Repair: Disconnect the P2 ECM connector. Measure
the resistance between the supply wire for the sus-
C. Inspect the terminals on the J2 and P2 ECM connectors pect compression brake solenoid and every terminal
for damage. on ECM connector P1 and ECM connector P2.
Measure the resistance between the supply wire for
Note: Refer to the Illustration 84 for pin locations. the suspect compression brake solenoid and engine
ground. If the wire is shorted, replace the wire.
D. Remove the return wire and the supply wire for the sus-
pect compression brake solenoid from the P2 ECM Measure the resistance between the return wire for
connector. the suspect compression brake solenoid and every
terminal on ECM connector P1 and ECM connector
E. Reconnect the P2 ECM connector. P2. If the wire is shorted, replace the wire.
F. Turn the keyswitch to the ON position. STOP
G. Access the “Special Tests” under the “Diagnostics” Result: A high current diagnostic code (-6) is logged.
menu. The ECM did not detect the open.
H. Start the “Compression Brake Solenoid Test” on the Repair: Replace the ECM. Refer to Troubleshooting,
electronic service tool. “ECM - Replace”. Verify that the problem is resolved.
I. Once the electronic service tool displays the status of the STOP
Solenoid Test” .
(continued)
188 UENR4542-04
Circuit Tests
(Table 102, contd)
7. Create a Short Circuit at the Compression Brake Diagnostic codes Result: A high current diagnostic code (-6) is logged.
Solenoid The harness wiring between the solenoid connector
for the suspect compression brake solenoid and
A. Turn the keyswitch to the OFF position. ECM connector P2 is OK.
B. Remove the valve cover. Repair: Temporarily connect a new compression

brake solenoid to the harness, but do not install the
C. Reconnect the valve cover connector. new compression brake solenoid in the engine. Veri-
fy that there are no active diagnostic codes for the
D. Disconnect the connector on the suspect compression compression brake solenoid. If there are no active di-
brake solenoid. agnostic codes for the compression brake solenoid,
permanently install the new compression brake sole-
E. Inspect the terminals on the solenoid connector for noid. Clear any logged diagnostic codes.
damage.
STOP
F. Fabricate a jumper wire to short the two wires for the sus-
pect solenoid on the solenoid connector. Crimp a pin to Result: A low current diagnostic code (-5) is cur-
each end of the jumper wire. rently active. The ECM did not detect the short
circuit.
G. Make sure that the solenoid connector securely holds
the jumper wire. Repair: Repair the harness between the connector
for the compression brake solenoid and the valve
Note: Worn terminals and/or damaged terminals on the sol- cover connector for the suspect compression brake
enoid connector could cause an intermittent “Open” . solenoid.
H. Turn the keyswitch to the ON position. STOP
I. Access the “Special Tests” under the “Diagnostics” menu.
J. Start the “Compression Brake Solenoid Test” on the elec-

K. Once the electronic service tool displays the status of

the compression brake solenoid, stop the “Compression
Brake Solenoid Test” .
L. Check for active diagnostic codes and/or logged diag-

brake solenoids.
8. Create an Open Circuit at the Compression Brake (05) Diagnostic Code Result: A low current diagnostic code (-5) is cur-
Solenoid rently active. The ECM detected the open at the
compression brake solenoid. The harness wiring be-
A. Turn the keyswitch to the OFF position. tween the solenoid connector for the suspect com-
pression brake solenoid and ECM connector P2 is
B. Reconnect the valve cover connector. OK.
C. Remove the valve cover. Repair: Temporarily connect a new compression

brake solenoid to the harness, but do not install the
D. Disconnect the connector on the suspect compression new compression brake solenoid in the engine. Veri-
brake solenoid. fy that there are no active diagnostic codes for the
compression brake solenoid. If there are no active di-
E. Inspect the terminals on the solenoid connector for agnostic codes for the compression brake solenoid,
damage. permanently install the new compression brake sole-
noid. Clear any logged diagnostic codes.
F. Turn the keyswitch to the ON position.
STOP
G. Access the “Special Tests” under the “Diagnostics”
menu. Result: A high current diagnostic code (-6) is logged.
The ECM did not detect the open.
(continued)
UENR4542-04 189
Circuit Tests
(Table 102, contd)

H. Start the “Compression Brake Solenoid Test” on the
electronic service tool. Repair: Repair the harness between the connector
for the compression brake solenoid and the valve
I. Once the electronic service tool displays the status of the cover connector for the suspect compression brake
compression brake solenoid, stop the “Compression Brake solenoid.
Solenoid Test” .
STOP
J. Check for active diagnostic codes and/or logged diag-
brake solenoids.
9. Check the Status of the Compression Brake Switch Status of Switch Result: The compression brake switch is operating
correctly.
A. Turn the keyswitch to the ON position.
Repair: If the problem is intermittent, refer to Trou-
B. Monitor the status for the compression brake switch on bleshooting, “Electrical Connectors - Inspect”.
the electronic service tool.
Result: There is a problem in the circuit for the com-
C. Operate the compression brake switch in the following pression brake switch.
positions:
• OFF
• LOW
• MEDIUM
• HIGH
10. Check the Switch Circuits at the J61/P61 Connector Status of the Switch Result: The status changed accordingly. There is a
Circuits problem in the wiring between J61 and the compres-
A. Turn the keyswitch to the OFF position. sion brake switch.
B. Disconnect the J61/P61 connector.
Repair: Repair the harness or replace the compres-
C. Insert a jumper wire between the following terminals on sion brake switch.
the P61 connector:
STOP
• Terminal 9
Result: There is a problem in the wiring between
• Terminal 34 P61 and the ECM.
D. Turn the keyswitch to ON position. Repair: Repair the harness or replace the harness
between P61 and the ECM.
E. Turn the keyswitch to OFF position.
F. Insert a jumper wire. Check the status for the compres-

sion brake switch on the electronic service tool. Remove
the jumper wire. e between the following terminals on the
P61 connector:
• Terminal 9
• Terminal 34
G. Turn the keyswitch to ON position.
H. Check the status for the compression brake switch on

190 UENR4542-04
Circuit Tests

steps are listed.
i06534847
Sensor Calibration Required -

Test
During normal operation, each pressure sensor

outputs a signal voltage that accurately represents
the pressure that is sensed by the sensor. However,
certain circuit conditions can cause a signal voltage
to become inaccurate.
During each key on event of at least 2 seconds, the
Electronic Control Module (ECM) evaluates the
signal voltage from each pressure sensor. The ECM
compares each signal voltage to a reference voltage.
The reference voltage that is used depends on the
sensor.
If a signal voltage is close to the reference voltage,
the ECM will internally adjust the signal voltage. The
internal adjustment causes the pressure value for the
sensor to be correct. This process is called automatic
sensor calibration.
If a signal voltage is not close to the reference
voltage, the ECM will not internally adjust the signal
voltage. The ECM will set a fault code that indicates
there is a problem with the signal voltage.
Refer to the troubleshooting procedure to determine
the root cause of the incorrect signal voltage.
Table 103
Code Description
J1939 Code PDL Code Comments
(code descriptions may vary)
During key on, the signal voltage from the fuel pressure sensor indi-
Engine Fuel Delivery Pressure : Out of cated a fuel pressure greater than +/- 27 kPa (3.9 psi) from the at-
94–13 94–13
Calibration mospheric pressure sensor.
Reference sensor : Atmospheric Pressure Sensor
During key on, the signal voltage from the engine oil pressure sen-
sor indicated an engine oil pressure greater than +/- 54 kPa (8 psi)
100–13 100–13 Engine Oil Pressure : Out of Calibration
from the atmospheric pressure sensor.
During key on, the signal voltage from the Intake Manifold pressure
Engine Intake Manifold #1 Absolute sensor indicated an Intake Manifold pressure greater than +/-
3563-13 1785–13
Pressure : Out of Calibration 18 kPa (3 psi) from the Atmospheric Pressure sensor.
UENR4542-04 191
Circuit Tests
Table 104
1. Check for Diagnostic Trouble Codes Diagnostic Result: There is an active or there is a logged -13 code.
Trouble
The engine coolant temperature must be greater than 0° C (32° F) Codes Proceed to Test Step 2.
before beginning this procedure.
A. Establish communication between the electronic service tool

and the Electronic Control Module (ECM) . Refer to Troubleshoot-
B. Wait at least 30 seconds in order for the diagnostic codes to be-

come active.
Look for an active -13 code or for a logged -13 code.
2. Check for Debris Debris Result: The sensor measurement port is not blocked by
debris.
B. Check the suspect sensor for debris.
Result: A -13 code is not present, return the unit to service.
C. If applicable, check the reference sensor for debris.
Result: A -13 code is present.
D. Check the sensor measurement port for blockage by debris.
Repair: Replace the suspect sensor. Verify that the problem
E. If debris is found, clear the debris from the measurement port is resolved.
and replace the suspect sensor.
Result: If more than one -13 code is present and the codes
F. Turn the keyswitch to the ON position. have a reference sensor, replace the reference sensor. Verify
that the problem is resolved.
G. Check for -13 codes. Wait at least 30 seconds in order for the di-
agnostic codes to become active.
3. Inspect the Suspect Sensor Connector Moisture Result: The suspect sensor connector has moisture and/or
corrosion.
Inspect the suspect sensor connector for moisture and/or
corrosion. Result: The suspect sensor connector does not have mois-
ture and/or corrosion.
(continued)
192 UENR4542-04
Circuit Tests
(Table 104, contd)

4. Remove any moisture and/or corrosion Moisture Result: A -13 code is not present, return the unit to service.
A. Disconnect the suspect sensor connector. Result: A -13 code is present.
B. Remove any moisture and/or corrosion from the outside of the Repair: Replace the suspect sensor. Verify that the problem
connector. Check for moisture and corrosion inside the connector. is resolved.
Verify that the seals for the wires are sealing correctly. Refer to
Troubleshooting, “Electrical Connectors - Inspect”, if necessary. Result: More than one -13 code is present and the codes
have a reference sensor.
C. If necessary, repair the connector or replace the connector.
Repair: Replace the reference sensor. Verify that the prob-
D. Reconnect the connector. Verify that the connection is secure. lem is resolved.
E. Turn the keyswitch to the ON position.
F. Monitor the diagnostic codes on the electronic service tool.

Check for -13 codes. Wait at least 30 seconds in order for the diag-
nostic codes to become active.
5. Check for Moisture and/or Corrosion in the Circuit Moisture Result: A -13 code is not present.
A. Check all the connectors in the circuit for moisture and/or Return the unit to service.
corrosion.
Result: A -13 code is present, replace the suspect sensor.
B. Check for corrosion inside the connector. Verify that the seals Verify that the problem is resolved.
for the wires are sealing correctly. Refer to Troubleshooting, “Elec-
trical Connectors - Inspect”, if necessary. Result: More than one -13 code is present and the codes
have a reference sensor.
C. If necessary, repair the connector or replace the connector.
Repair: Replace the reference sensor. Verify that the prob-
D. Reconnect the connector. Verify that the connection is secure. lem is resolved.
F. Monitor the diagnostic codes on the electronic service tool.

Check for -13 codes. Wait at least 30 seconds in order for the diag-
nostic codes to become active.

steps are listed.
i06624615
Sensor Signal (Analog, Active)

- Test

codes:
UENR4542-04 193
Circuit Tests
Table 105

The Electronic Control Module (ECM) detects a signal voltage from
the sensor that is above normal.
Engine Fuel Delivery Pressure
94-3 94-3 The code is logged. The ECM flags fuel pressure as invalid data and
: Voltage Above Normal
a default value is used.
There are no performance effects.
The ECM detects a signal voltage that is below normal.
Engine Fuel Delivery Pressure The code is logged. The ECM flags fuel pressure as invalid data and
94-4 94-4
: Voltage Below Normal a default value is used.
The ECM detects a signal voltage that is above normal.
Engine Oil Pressure : Voltage The code is logged. The ECM flags oil pressure as invalid data and
100-3 100-3
Above Normal a default value is used.
Engine Oil Pressure : Voltage The code is logged. The ECM flags oil pressure as invalid data and
100-4 100-4
Below Normal a default value is used.
The signal voltage from the atmospheric pressure sensor is above

4.8 VDC for at least 8 seconds.
Barometric Pressure : Voltage
108-3 274-3
Above Normal The ECM will log the diagnostic code. The ECM flags atmospheric
pressure as invalid data and a default value of 100 kPa (15 psi) is
used.
The signal voltage from the atmospheric pressure sensor is below
normal.
Barometric Pressure : Voltage
108-4 274-4 The ECM will log the diagnostic code. The ECM flags atmospheric
Below Normal
pressure as invalid data and a default value is used.
The engine may experience low power.
The signal from the auxiliary temperature sensor is above normal.

Engine Injection Control Pres-
1387-3 1835-3 The ECM will log the diagnostic code. The auxiliary temperature is
sure : Voltage Above Normal
set to the default value.
The signal from the auxiliary temperature sensor is below normal.

Engine Injection Control Pres-
1387-4 1835-4 The ECM will log the diagnostic code. The auxiliary temperature is
sure : Voltage Below Normal
set to the default value.
(continued)
194 UENR4542-04
Circuit Tests
(Table 105, contd)


The signal voltage from the intake manifold pressure sensor is
above normal.
Intake Manifold Pressure Sen-
3563-3 1785-3 The ECM will log the diagnostic code. The ECM will flag the intake
sor : Voltage Above Normal
manifold pressure as invalid data and a default value is used.
The signal voltage from the intake manifold pressure sensor is be-
low normal.
Intake Manifold Pressure Sen-
3563-4 1785-4 The ECM will log the diagnostic code. The ECM will flag the intake
sor : Voltage Below Normal
manifold pressure as invalid data and a default value is used.
Use this procedure to troubleshoot any suspect If the sensor is disconnected at the sensor connector
problems with the following sensors: and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
• Injection actuation pressure sensor wire is shorted to another wire in the harness.
• Intake manifold pressure sensor

• Atmospheric pressure sensor
• Fuel pressure sensor

• Engine oil pressure sensor
• Auxiliary pressure sensor (if equipped)

The troubleshooting procedures for the diagnostic
codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a 5 V supply to
terminal A of each sensor. The sensor common
connection is connected to terminal B of each sensor.
The signal voltage from terminal C of each sensor is
sent to the appropriate ECM connector.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the circuit for the sensor signal wire. The ECM uses
this pull-up voltage to detect an open in the signal
circuit. When the ECM detects the presence of a
voltage that is above a threshold on the signal wire,
the ECM will generate a -3 diagnostic code.
If the sensor is disconnected at the sensor connector,
the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the
return wire from the sensor connector to the ECM are
good.
the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.
UENR4542-04 195
Circuit Tests
Schematic for the engine pressure sensors
196 UENR4542-04
Circuit Tests
P1 terminals that are associated with the engine
pressure sensors
(P1-2) +5 VDC
(P1-3) Return
(P1-15) Auxiliary pressure
P2 ECM connector
(P2-15) Signal from the boost pressure sensor
(P2-17) Sensor return
(P2-28) Signal from the oil pressure sensor
(P2-40) Signal from the fuel pressure sensor
(P2-57) Atmospheric pressure sensor signal
(P2-72) +5 V sensor supply
UENR4542-04 197
Circuit Tests
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
engine pressure sensors
(14) +5 VDC
(15) Return
(33) Auxiliary pressure
198 UENR4542-04
Circuit Tests
Table 106
1. Inspect the Electrical Connectors and Wiring Electrical Connectors Results: The harness and wiring are OK. Proceed to
and Wiring Test Step 2.
Results: There is a problem in the wiring and/or the
B. Thoroughly inspect the P1/J1 and P2/J2 ECM connec- connectors.
tors. Thoroughly inspect the connectors for each engine
pressure sensor. Refer to Troubleshooting, “Electrical Repair: Repair the wiring and/or the connectors. Re-
Connectors - Inspect”. place parts, if necessary. Ensure that all the seals are
properly in place and ensure that the connectors are
C. Perform a 45 N (10 lb) pull test on each of the wires coupled. Verify that the problem is resolved.
that are associated with the engine pressure sensors.
STOP
D. Check the allen head screw on each ECM connector
for the proper torque. Refer to Troubleshooting, “Electrical
Connectors - Inspect”.
E. Check the harness and wiring for abrasions and for

pinch points from each sensor back to the ECM.
2. Check the Voltage on the +5 V Supply Wire 5.0 ± 0.2 VDC Results: Each voltage measurement is 5.0 ± 0.2 VDC.
Results: At least one voltage measurement is not 5.0 ±
B. Disconnect the harness connectors for the following 0.20 VDC.
sensors:
Repair: Refer to Troubleshooting, “Sensor Supply -
· Injection actuation pressure sensor J500/P500 Test”.
· Boost pressure sensor J200/P200 STOP
· Atmospheric pressure sensor J203/P203
· Fuel pressure sensor J209/P209
· Engine oil pressure sensor J201/P201
· Auxiliary pressure sensor J220/P220 (if equipped)
D. Measure the voltage between terminals A (+5 VDC)

and B (Return) at each sensor connector on the engine
harness.
E. Turn the keyswitch to the OFF position.
F. Connect all the sensors.
(continued)
UENR4542-04 199
Circuit Tests
(Table 106, contd)
3. Check for Codes Codes Results: No diagnostic codes are active for the engine
pressure sensors.
A. Connect the electronic service tool to the service tool
connector. Repair: If any of the above codes are logged and the
engine is not running properly, refer to Troubleshooting,
B. Turn the keyswitch to the ON position. “Symptom Troubleshooting”.
C. Observe the “Active Diagnostic” screen on the elec- If the engine is running properly, there may be an inter-
tronic service tool. Wait at least 15 seconds so that any co- mittent problem in a harness that is causing the codes to
des may become active. Look for an active diagnostic be logged. Refer to Troubleshooting, “Electrical Connec-
code for an engine pressure sensor. tors - Inspect”.
D. Determine if the problem is related to a -3 diagnostic STOP

code or a -4 diagnostic code.
Results: A -4 diagnostic code is active. Proceed to Test
Step 4.
Results: A -3 diagnostic code is active. Proceed to Test

Step 5.
4. Disconnect the Suspect Sensor in Order to Create Code Results: A -4 diagnostic code was active before you
an Open Circuit disconnected the sensor. A -3 diagnostic code became
active after the sensor was disconnected.
Repair: Temporarily connect a new sensor to the har-
B. Disconnect the sensor connector of the sensor with the ness, but do not install the new sensor in the engine.
-4 diagnostic code. Verify that there are no active diagnostic codes for the
sensor. If there are no active diagnostic codes for the
C. Turn the keyswitch to the ON position. Wait at least 15 sensor, permanently install the new sensor. Clear any
seconds for activation of the diagnostic codes. logged diagnostic codes.
D. Access the “Active Diagnostic Code” screen on the STOP

electronic service tool. Check for an active -3 diagnostic
code for the disconnected sensor. Results: A -4 diagnostic code was active before you
disconnected the sensor. The -4 diagnostic code re-
E. Turn the keyswitch to the OFF position. mained after the sensor was disconnected. Leave the
sensor disconnected. Proceed to Test Step 8.
5. Check the Pull-up Voltage at the Sensor Connector 11 ± 2 VDC Results: The voltage is 11 ± 2 VDC. The signal wire to
the ECM from the sensor connector is OK.
A. Turn the keyswitch to the ON position.
Repair: The open circuit is in the sensor or the wire be-
B. Disconnect the suspect sensor. tween the sensor and the sensor connector. Temporarily
connect a new sensor to the engine harness. Do not in-
C. Measure the voltage between terminals C (signal) and stall the sensor in the engine. Verify that no diagnostic
B (sensor return) at the harness connector for the sensor. codes are active for the new sensor before you perma-
nently install the sensor.
D. Turn the keyswitch to the OFF position.
STOP
Results: The voltage is not 11 ± 2 VDC. Proceed to Test

Step 6.
(continued)
200 UENR4542-04
Circuit Tests
(Table 106, contd)
6. Check the Signal Wire for a Short Circuit Open Circuit Results: Each resistance measurement indicates an
B. Disconnect the J1/P1 and J2/P2 connectors. Results: At least one resistance measurement does not
indicate an open circuit. There is a problem in the wiring
C. Disconnect the harness connector for the suspect for the sensor. There may be a problem with a
sensor. connector.
D. Identify the terminal for the signal wire on the ECM con- Repair: Repair the wiring and/or the connector. Replace
nector that is appropriate for the suspect sensor. Measure parts, if necessary. Verify that the problem is resolved.
the resistance between the appropriate terminal and the
remaining terminals on both ECM connectors. STOP
E. Measure the resistance between the appropriate termi-

nal and the engine ground.
F. Connect J1/P1 and J2/P2 connectors. Connect the con-

nectors for the suspect sensor.
7. Create a Short at the Suspect Sensor Connector Codes Results: A -4 diagnostic code was active when the
jumper wire was installed. A -3 diagnostic code became
A. Turn the keyswitch to the OFF position. active when the jumper wire was removed. The engine
harness and the ECM are OK.
B. Install a jumper wire with Deutsch sockets on each end
between terminals B (sensor return) and C (signal) on the Repair: Temporarily connect a new sensor to the har-
harness connector for the suspect sensor. ness, but do not install the new sensor in the engine.
Verify that there are no active diagnostic codes for the
C. Turn the keyswitch to the ON position. sensor. If there are no active diagnostic codes for the
new sensor, permanently install the new sensor. Clear
Note: Monitor the “Active Diagnostic Codes” screen on any logged diagnostic codes. Verify that the problem is
the electronic service tool before installing the jumper wire resolved.
and after installing the jumper wire.
STOP
D. Observe the “Active Diagnostic Codes” screen on the
electronic service tool. Wait at least 15 seconds so that Results: A -4 diagnostic code was active when the
any codes may become active. Look for a -4 diagnostic jumper wire was installed. The -4 code remained when
code. the jumper wire was removed. Proceed to Test Step 8.
E. Remove the jumper wire.

UENR4542-04 201
Circuit Tests
Table 107
8. Check the Operation of the ECM -3 diagnostic code Result: The ECM is operating properly. There
is a problem in the wiring between the ECM
A. Turn the keyswitch to the OFF position. and the sensor connector.
B. Check the operation of the ECM by creating Repair: If the code is active for more than one
an open at the ECM. sensor, the problem is most likely in the return
wire for the sensor. The problem may be in a
Note: Disconnecting the return wire from the connector. Repair the return wire and/or the
ECM will generate an open circuit diagnostic connector. Replace parts, if necessary. If the
code for all sensors that are connected to the code is only active for one sensor, the problem
return wire. Ignore the additional codes. Trou- is most likely in the signal wire for the sensor.
bleshoot the original diagnostic code and clear Repair the signal wire and/or the connector.
the codes when you are finished. Replace parts, if necessary. Verify that the
STOP
D. Monitor the “Active Diagnostic Code”
screen on the electronic service tool. Wait at Results: One of the following conditions ex-
least 15 seconds so that any codes may be- ists: The -3 diagnostic code is not active when
come active. the signal wire is disconnected. The -4 diag-
nostic code is not active when the wire jumper
Note: A -3 diagnostic code should be active is installed.
for the suspect sensor.
E. Turn the keyswitch to the OFF position. shooting, “ECM - Replace”. Verify that the
F. Check the operation of the ECM by creating
a short circuit at the ECM. STOP
G. Turn the keyswitch to the ON position.
H. Monitor the “Active Diagnostic Code”

screen on the electronic service tool. Wait at
least 15 seconds so that any codes may be-
come active.
Note: A short circuit diagnostic code (-4)

should be active when the wire jumper is
installed.
I. Turn the keyswitch to the OFF position.
J. Remove the jumper wire. Return the wiring

to the original configuration.
i06624648
Sensor Signal (Analog,

Passive) - Test

codes:
202 UENR4542-04
Circuit Tests
Table 108

The engine coolant temperature is above −10° C (14° F). The signal
voltage from the intake manifold air temperature sensor is greater
Engine Intake Manifold #1
than 4.95 V for more than 8 seconds.
105–3 172–3 Temperature : Voltage Above
The Electronic Control Module (ECM) will log the diagnostic code.
Normal
The ECM flags engine coolant temperature as invalid data and a de-
fault value of 40° C (104° F) is used.

Engine Intake Manifold #1
The code is logged. The ECM will flag the intake manifold air tem-
105–4 172–4 Temperature : Voltage Below
perature as invalid data and the intake manifold air temperature is
Normal
set to a default value.
The Electronic Control Module (ECM) detects the following
conditions:
The engine has been running for more than 7 minutes.

The signal voltage from the engine coolant temperature sensor is
greater than 4.95 VDC for more than 8 seconds.
Engine Coolant Temperature : The ECM will log the diagnostic code if the engine has been running
110-3 110-3
Voltage Above Normal for more than 7 minutes. The check engine lamp will illuminate after
a delay.
The ECM will set the value of the coolant temperature to a default
value.
The engine will not go into cold mode when this diagnostic code is
active.
The ECM will activate the cooling fan after this code has been active
for more than 8 seconds.
The ECM detects the following conditions:
The engine has been running for more than 7 minutes.

The signal voltage from the engine coolant temperature sensor is
less than 0.2 VDC for more than 8 seconds.
Engine Coolant Temperature : The ECM will log the diagnostic code. The check engine lamp will il-
110-4 110-4
Voltage Below Normal luminate after a delay.
The ECM will set the value of the coolant temperature to a default
value.
The engine will not go into cold mode when the diagnostic code is
active.
The ECM will activate the cooling fan after this code has been active
for more than 8 seconds.
The code is logged. The ECM will flag the fuel temperature as inva-
Engine Fuel Temperature 1 : lid data and the fuel temperature is set to a default value of 40° C
174-3 174-3
Voltage Above Normal (104° F).
The code is logged. The ECM will flag the fuel temperature as inva-
Engine Fuel Temperature 1 : lid data and the fuel temperature is set to a default value of 40° C
174-4 174-4
Voltage Below Normal (104° F).
The ECM detects a signal voltage from the auxiliary temperature

Auxiliary Temperature #1 : sensor that is above normal.
441–3 1836–3
Voltage Above Normal The ECM logs the diagnostic code. The auxiliary temperature is set
to the default value.
The Electronic Control Module (ECM) detects a signal voltage from
Auxiliary Temperature #1 : the auxiliary temperature sensor that is below normal.
441–4 1836–4
Voltage Below Normal The ECM logs the diagnostic code. The value of the auxiliary tem-
perature is set to a default value.
UENR4542-04 203
Circuit Tests
Use this procedure to troubleshoot any suspect

problems with the following sensors:
• Coolant temperature sensor

• Intake manifold air temperature sensor
• Fuel temperature sensor

• Auxiliary temperature sensor
The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical. The
temperature sensors are passive sensors that have
two terminals. The temperature sensors do not
require supply voltage from the Electronic Control
Module (ECM).
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the circuit for the sensor signal wire. The ECM uses
this pull-up voltage to detect an open in the signal
circuit. When the ECM detects the presence of a
voltage that is above a threshold on the signal wire,
the ECM will generate a -3 diagnostic code.
the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the
return wire from the sensor connector to the ECM are
good.
the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.
If the sensor is disconnected at the sensor connector
and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
204 UENR4542-04
Circuit Tests
Schematic for the engine temperature sensors
UENR4542-04 205
Circuit Tests
J1/P1 terminals that are associated with the engine
temperature sensors
(3) Return
(16) Auxiliary temperature
P2 terminations for the engine temperature sensors
(P2-13) Engine coolant temperature
(P2-30) Return
(P2-56) Intake manifold air temperature
(P2-62) Fuel temperature
206 UENR4542-04
Circuit Tests
auxiliary temperature sensor
(9) Return
(11) Auxiliary temperature
Harness connector for the temperature sensors
(1) Signal
(2) Return
UENR4542-04 207
Circuit Tests
Table 109
1. Inspect the Electrical Connectors and the Wiring Electrical Connectors and Results: The connectors and wiring are OK. Pro-
Wiring ceed to Test Step 2.
Results: There is a problem in the connectors and/
B. Thoroughly inspect the J1/P1 ECM connectors. Inspect or wiring.
the sensor connectors. Refer to Troubleshooting, “Electri-
cal Connectors - Inspect”. Repair: Repair the wiring and/or the connectors. Re-
place parts, if necessary. Ensure that all the seals
C. Perform a 45 N (10 lb) pull test on each of the wires that are properly in place and ensure that the connectors
are associated with the temperature sensors. are coupled. Verify that the repair eliminates the
problem.
D. Check the allen head screw on the ECM connectors for
the proper torque. Refer to Troubleshooting, “Electrical STOP
Connectors - Inspect”.
E. Check the allen head screw on the customer connectors

for the proper torque of 2.25 ± .25 N·m (20 ± 2 lb in).
F. Check the harness and wiring for abrasions and for pinch
points from each sensor to the ECM.
2. Check for Codes Diagnostic codes Results: No diagnostic codes are active.
A. Connect the electronic service tool to the service tool Repair: The problem may have been related to a
connector. faulty connection in the harness. Carefully reinspect
the connectors and wiring. Refer to Troubleshooting,
B. Turn the keyswitch to the ON position. “Electrical Connectors - Inspect” for additional
information.
C. Monitor the active diagnostic code screen on the elec-
tronic service tool. Check and record any active diagnostic STOP
codes.
Results: A -4 diagnostic code is active. Proceed to
Note: Wait at least 15 seconds in order for the diagnostic Test Step 3.
codes to become active.
Results: An -3 diagnostic code is active. Proceed to
D. Look for an -3 diagnostic code or a -4 diagnostic code. Test Step 4.
3. Disconnect the Suspect Sensor in Order to Create Diagnostic codes Results: A -4 diagnostic code was active before dis-
an Open Circuit connecting the sensor. A -3 diagnostic code became
active after the sensor was disconnected.
Repair: Temporarily connect a new sensor to the
B. Disconnect the suspect sensor from the engine harness. harness, but do not install the new sensor in the en-
gine. Verify that there are no active diagnostic codes
C. Turn the keyswitch to the ON position. Wait at least 15 for the sensor. If there are no active diagnostic codes
seconds for activation of the diagnostic codes. for the sensor, permanently install the new sensor.
Clear any logged diagnostic codes. Verify that the re-
D. Access the “Active Diagnostic Codes” screen on the pair eliminates the problem.
electronic service tool and check for an active -3 diagnostic
code for the suspect sensor. STOP
E. Turn the keyswitch to the OFF position. Results: The -4 diagnostic code is still present.
Leave the sensor disconnected. Proceed to Test
Step 7.
(continued)
208 UENR4542-04
Circuit Tests
(Table 109, contd)
4. Check the Pull-up Voltage at the Sensor Connector 5.5 ± 0.5 VDC Results: The voltage is 5.5 ± 0.5 VDC. The correct
pull-up voltage is present at the harness connector
A. Disconnect the suspect sensor at the sensor connector. for the suspect sensor.
B. Turn the keyswitch to the ON position. Repair: The open circuit is in the sensor or the wire
between the sensor and the sensor connector. Re-
C. Measure the voltage between terminal 1 (signal) and ter- place the sensor. Do not install the sensor in the en-
minal 2 (return) at the harness connector. gine. Verify that no diagnostic codes are active for
the suspect sensor before permanently installing the
D. Turn the keyswitch to the OFF position. sensor.
STOP
Results: The voltage is not 5.5 ± 0.5 VDC. Proceed

to Test Step 5.
5. Create a Short at the Suspect Sensor Connector Resistance Results: Each check of the resistance indicates an
Results: At least one check of the resistance does
B. Disconnect the P1 and P2 connectors. not indicate an open circuit. There is a problem with
the wiring. There may be a problem with a connector.
C. Measure the resistance between the terminal for the
suspect sensor signal wire at the ECM connector and all Repair: Repair the wiring and/or the connectors. Re-
the remaining terminals on the P2 connector. place parts, if necessary. Verify that the original prob-
lem is resolved.
D. Measure the resistance between the terminal for the
suspect sensor signal wire at the ECM connector and all STOP
the remaining terminals on the P1 connector.
E. Measure the resistance between the terminal for the

suspect sensor signal wire at the ECM connector and the
engine ground.
F. Connect the J1/P1 and J2/P2 connectors.
6. Create a Short at the Suspect Sensor Connector Diagnostic codes Results: The engine harness and the ECM are OK.
A. Turn the keyswitch to the OFF position. Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the en-
B. Install a jumper wire between terminals 1 and 2 on the gine. Verify that there are no active diagnostic codes
harness connector for the suspect sensor. for the sensor. If there are no active diagnostic codes
for the sensor, permanently install the new sensor.
C. Turn the keyswitch to the ON position. Clear any logged diagnostic codes.
D. Wait at least 15 seconds for activation of the -4 diagnos- STOP

tic code.
Results: The -3 diagnostic code remains active with
Note: Monitor the “Active Diagnostic Codes” screen on the the jumper in place. Proceed to Test Step 7.
electronic service tool before installing the jumper wire and
after installing the jumper wire.
E. Remove the jumper wire. Check for a -4 diagnostic code

again.

UENR4542-04 209
Circuit Tests
Table 110
7. Check the Operation of the ECM Diagnostic codes Results: The ECM is working properly. The
problem is in the wiring between the ECM and
A. Turn the keyswitch to the OFF position. the sensor connector.
B. Check the operation of the ECM by creating Repair: If the code is active for more than one
an open circuit at the ECM: sensor, the problem is most likely in the return
wire for the sensor. Repair the return wire for
1. Remove the signal wire for the suspect sen- the sensor or replace the harness. If the code
sor from the appropriate ECM connector. is only active for one sensor, the problem is
most likely in the signal wire for the sensor. Re-
2. Remove terminal P2-30 (return). pair the signal wire for the sensor.
Note: Disconnecting the return wire from the STOP

ECM will generate a -3 diagnostic code for all
sensors that are connected to the return wire. Results: One of the following conditions ex-
Troubleshoot the original diagnostic code. ists: The -3 diagnostic code is not active when
Clear the logged diagnostic codes when you the sensor signal wire is disconnected. The -4
are finished. diagnostic code is not active when the wire
jumper is installed.
3. Turn the keyswitch to the ON position. Moni-
tor the “Active Diagnostic Code” screen on the Repair: Replace the ECM. Refer to Trouble-
electronic service tool. Wait at least 15 sec- shooting, “ECM - Replace”. Verify that the orig-
onds for activation of the code. inal problem is resolved.
A -3 diagnostic code should be active for the STOP

suspect sensor.
C. Check the operation of the ECM by creating
a short at the ECM:
1. Install a wire jumper between the terminals

for the sensor signal wire and the return wire.
2. Monitor the “Active Diagnostic Code” screen

on the electronic service tool. Wait at least 15
seconds for activation of the code.
Note: A -4 diagnostic code should be active

when the wire jumper is installed.
3. Remove the wire jumper. Return all wiring to

the original configuration.
i05967789
Sensor Supply - Test

(8 V Supply)
The Electronic Control Module (ECM) supplies a

regulated voltage of 8.0 ± 0.4 VDC to terminal A of
the engine coolant level sensor. This sensor is
optional equipment.
codes:
210 UENR4542-04
Circuit Tests
Table 111

The voltage level of the 8 V supply is above normal.
ECU 8 Volts DC Supply : Volt- The Electronic Control Module (ECM) will log the diagnostic code.
678-3 41-3
age Above Normal The ECM flags all digital sensors as invalid data and all digital sen-
sors are set to the respective default values.
The voltage level of the 8 V supply is below normal.
ECU 8 Volts DC Supply : Volt- The ECM logs the diagnostic code. The ECM flags all digital sensors
678-4 41-4
age Below Normal as invalid data and all digital sensors are set to the respective de-
fault values.
A +8 V diagnostic code is probably caused by a short

circuit to ground or a short circuit to another voltage
source in the harness. The next likely cause is a
problem with a sensor. The least likely cause is a
problem with the ECM.
Schematic for the digital sensor supply
UENR4542-04 211
Circuit Tests

Left side view P1 ECM connector
(1) P61 customer connector (P1-4) +8 VDC (digital sensor supply)
(2) J1/P1 ECM connectors (P1-5) Return
212 UENR4542-04
Circuit Tests

J61 and P61 customer connectors
(8) +8 VDC (digital sensor supply)
(9) Return
Table 112
1. Inspect the Electrical Connectors and Electrical Connectors and Wiring Results: The connectors and the wiring are
the Wiring OK. Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. Results: There is a problem with a connector
and/or the wiring.
B. Thoroughly inspect connectors (1) and (2).
Inspect the connectors for each digital sensor. Repair: Repair the connector and/or the wir-
Refer to Troubleshooting, “Electrical Connec- ing. Replace parts, if necessary. Ensure that
tors - Inspect” for details. all of the seals are properly in place and en-
sure that the connectors are completely
C. Perform a 45 N (10 lb) pull test on each of coupled. Verify that the problem is resolved.
the wires that are associated with the digital
sensor supply. STOP

E. Check the harness and wiring for abrasions

and for pinch points from the battery to the
ECM.
(continued)
UENR4542-04 213
Circuit Tests
(Table 112, contd)
2. Check for Codes Codes Results: A 41-3 diagnostic code is active. Pro-
A. Connect the electronic service tool to the
service tool connector. Results: A 41-4 diagnostic code is active. Pro-
B. Observe the active diagnostic code screen
on the electronic service tool. Wait at least 15 Results: None of the above codes are active.
seconds so that any codes may become ac-
tive. Look for these codes: Repair: If any of the above codes are logged
and the engine is not running properly, refer to
· 41-3 8 Volt DC Supply short to +batt Troubleshooting, “Symptom Troubleshooting”.
· 41-4 8 Volt DC Supply short to ground STOP
3. Check the Voltage on the +8 V Supply 8.0 ± 0.4 VDC Results: The voltage measurement is 8.0 ±
Wire 0.4 VDC.
A. Turn the keyswitch to the OFF position. Repair: Connect the sensor connectors. Clear
all diagnostic codes. Check for active diagnos-
B. Disconnect the harness connectors for the tic codes. If the problem is intermittent, refer to
engine coolant level sensor J800/P800. Troubleshooting, “Electrical Connectors -
Inspect”.
STOP
D. Measure the voltage between terminals A
and B at the harness connector for the sensor. Results: The voltage measurement is not 8.0
± 0.4 VDC. There is a problem with the wiring
or with the ECM. Proceed to Test Step 5.
4. Disconnect the +8 V Digital Sensor and 41-4 Code Results: The 41-4 diagnostic code deacti-
Check for Active Diagnostic Codes vates when a particular sensor is
disconnected.
A. Disconnect the Engine coolant level sensor.
Repair: Connect the suspect sensor. If the di-
B. Wait for 15 seconds after you disconnect agnostic code returns, replace the sensor.
each sensor. Look for the active 41-4 diagnos- Connect all of the connectors. Verify that the
tic code to deactivate. problem is resolved.
STOP
Results: The 41-4 diagnostic code remains

after all of the sensors are disconnected.
Leave the sensors disconnected. Proceed to
Test Step 5.
(continued)
214 UENR4542-04
Circuit Tests
(Table 112, contd)
5. Check the +8 V Supply Wire for a Short Open circuit Results: Each check of the resistance indi-
Circuit cates an open circuit. Proceed to Test Step 6.
A. Turn the keyswitch to the OFF position. Results: At least one check of the resistance
does not indicate an open circuit. A +8 V sup-
B. Disconnect the J1/P1 and J2/P2 ply wire has a problem. There may be a prob-
connectors. lem with a connector.
C. Verify that all of the digital sensors are Repair: Repair the wire and/or the connector,
disconnected. when possible. Replace parts, if necessary.
Verify that the problem is resolved.
Note: Wiggle the harness during the following
measurements in order to reveal an intermit- STOP
tent condition.
D. Measure the resistance between P1-4 (+8

V supply) and the remaining terminals on the
P1 and P2 connectors.
E. Measure the resistance between P1-4 (+8
VDC supply) and the engine ground.
6. Check the +8 V Supply and the Sensor Less than ten Ohms Results: Each resistance measurement is
Common for an Open Circuit less than ten Ohms. Proceed to Test Step 7.
A. Install a jumper wire between terminals P1- Results: At least one resistance measurement
4 (+8 V supply) and P1-5 (Return). is more than ten Ohms. A +8 V supply wire or
a return wire has excessive resistance. There
Note: Wiggle the harness during the following may be a problem with a connector.
measurement in order to reveal any intermit-
tent short condition. Repair: Repair the wires and/or the connector,
B. Measure the resistance between terminals when possible. Replace parts, if necessary.
A and B at the harness connector for each digi- Verify that the problem is resolved.
tal sensor.
STOP
C. Remove the jumper wire.
7. Check the +8 V Supply at the ECM 8.0 ± 0.4 VDC Results: The voltage measurement is 8.0 ±
0.4 VDC.
A. Remove terminal 4 from the P1 connector.
Install a jumper wire with socket terminals on Repair: Clear all diagnostic codes. Check for
both ends into P1-4. active diagnostic codes. If the problem is inter-
mittent, refer to Troubleshooting, “Electrical
B. Remove terminal 5 from the P1 connector. Connectors - Inspect”.
Install a jumper wire with socket terminals on
both ends into P1-5. Results: The voltage measurement is not 8.0
± 0.4 VDC.
C. Connect the P1 connector.
D. Turn the keyswitch to the ON position. shooting, “ECM - Replace”.
E. Measure the voltage between the jumper STOP

wires in P1-4 and P1-5.
G. Restore all wiring to the original

configuration.
UENR4542-04 215
Circuit Tests
i06624751
Sensor Supply - Test

(5V Supply)

system if a problem is suspected with a sensor
supply. Use this procedure if any one of the
diagnostic codes in Table 113 is active or easily
repeated.

Table 113
Diagnostic Codes Table
Code Description
The code is logged.

Engine Oil Pressure : Abnormal
100–10 100–10 The sensor supply to the engine oil pressure sensor
Rate of Change
has been lost
Sensor Supply Voltage 1 : Voltage The code is logged.
3509–3 262–3
Above Normal All sensors are set to default values.
3509–4 262–4
Below Normal All sensors are set to default values.

3510–3 2131–3
Above Normal Engine power may be derated

3510–4 2131–4
Below Normal Engine power may be derated
Engine Intake Manifold #1 Absolute The code is logged.

3563–10 1785–10 Pressure : Abnormal Rate of The sensor supply to the intake manifold pressure
Change sensor has been lost
System Operation
The Electronic Control Module (ECM) supplies a
regulated voltage of 5.0 ± 0.2 VDC to the sensors.
The supply voltage for the sensors is routed from the
ECM to terminal A of each sensor connector. The
sensor return for the sensors is routed from the ECM
to terminal B of each sensor connector. The ECM
provides short circuit protection for the internal power
supply. A short circuit to the battery will not damage
the internal power supply.
Note: The sensors are not protected from
overvoltage. A short from the supply line to the
+Battery may damage the sensors. If any of the
diagnostic codes are active, a sensor may have been
damaged. Repair the sensor supply and check for
any active sensor diagnostic codes to determine if a
sensor has been damaged.
216 UENR4542-04
Circuit Tests
Table 114
Sensor Supply Sensor Supply ECM Location
Sensor Supply #1 Sensors on A4:E4 engine ECM J2 connector
Sensor Supply #2 Sensors on A4:E4 engine ECM J1 connector

Schematic for the 5 V supply
UENR4542-04 217
Circuit Tests
Note: The diagram above is a simplified schematic of

the ECM - sensor circuit. The schematic is electrically
correct. However, not all the possible sensors or
harness connectors are shown. Refer to the latest
revision of the Electrical Schematic for the complete
schematic for your engine.

Locations of the sensors on 2506 and 2806D engines
(1) Intake manifold (Boost) pressure sensor (3) J1/P1 ECM connector (5) Atmospheric pressure sensor
(2) Fuel pressure sensor (4) J2/P2 ECM connector (6) Engine oil pressure sensor
218 UENR4542-04
Circuit Tests

Locations of the sensors on 2206D engines
(1) Atmospheric pressure sensor (3) Engine oil pressure sensor (5) J2/P2 ECM connector
(2) Fuel pressure sensor (4) Intake manifold (Boost) pressure sensor (6) J1/P1 ECM connector
UENR4542-04 219
Circuit Tests

P1 terminals that are associated with the 5 V supply
for the pressure sensors
(P1-2) +5 VDC
(P1-3) Return

P2 terminals that are associated with the 5 V supply
for the pressure sensors
(P2-17) Return
(P2-54) Return
(P2-72) +5 VDC
(P2-80) +5 VDC
220 UENR4542-04
Circuit Tests

J61/P61 terminals that are associated with the 5 V
supply for the pressure sensors
(14) +5 VDC
(15) Return

Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
UENR4542-04 221
Circuit Tests
Table 115
1. Determine the Code Diagnostic Result: A -3 or -4 code is present.

Codes
A. Connect the electronic service tool to the service tool connec- Proceed to Test Step 2.
tor. Refer to Troubleshooting, “Electronic Service Tools”, if
necessary. Result: A -10 code is present.
B. Turn the keyswitch to the ON position. Repair: Proceed to Test Step 3.
C. Determine if a diagnostic trouble code is present.
2. Check for a Failed Sensor Failed Result: The suspect sensor supply active code changes to
Sensor logged when a sensor is unplugged.
A. Connect to the electronic service tool.
Repair: Replace the failed sensor.
B. Turn the keyswitch to the ON position. Verify that the repair resolved the problem.
C. Disconnect a sensor on the suspect sensor supply circuit. Result: The suspect sensor supply active code remains
active after all sensors on the sensor supply circuit have
D. Monitor the electronic service tool when the sensor is discon- been checked.
nected to see if the active code changes to logged. A failed wiring harness has been detected.
E. Connect the suspect sensor to the wiring harness Repair: Repair or replace the wiring harness.
Verify that the repair resolved the problem.
F. Repeat steps C through E for each sensor on the suspect sen-
sor supply.
3. Check the Voltage on the +5 V Supply Wire 5.0 ± 0.2 Result: The voltage measurement is 5.0 ± 0.2 VDC.
VDC
A. Turn the keyswitch to the OFF position. Repair: Connect all the sensor connectors. Clear all diag-
nostic codes. Check for active diagnostic codes. If the
B. Disconnect the harness connector for the sensor with the -10 problem is intermittent, refer to Troubleshooting, “Electrical
diagnostic code. Connectors - Inspect”.
C. Turn the keyswitch to the ON position. STOP
Note: Be sure to wiggle the harness during the following meas- Result: The voltage measurement is 5.0 ± 0.2 VDC. The 5
urements to reveal an intermittent condition. V supply is present at the harness connector for the sus-
pect sensor. However, there is an active 10 diagnostic
D. Measure the voltage between terminals A and B at the sus- code.
pect sensor connector on the engine harness.
Repair: Replace the suspect sensor.
STOP
Result: The voltage measurement is not 5.0 ± 0.2 VDC.

There is a problem with the wiring or with the ECM.
(continued)
222 UENR4542-04
Circuit Tests
(Table 115, contd)
4. Check the +5 V Supply Wire for a Short to Engine Ground Open Result: Each resistance measurement indicates an open
or a Short Circuit Circuit circuit.
A. Turn the keyswitch to the OFF position. Proceed to Test Step 5.
B. Disconnect the J2/P2 ECM connector. Disconnect the J1/P1 Result: At least one of the resistance measurements does
ECM connector. not indicate an open circuit. A +5 V supply wire has a prob-
lem. There may be a problem with a connector.
C. Verify that all the pressure sensors are disconnected.
Repair: Repair the wire and/or the connector, when possi-
Note: Wiggle the harness during the following measurements to ble. Replace parts, if necessary. Verify that the problem is
reveal an intermittent condition. resolved.
D. For the intake manifold pressure sensor, perform the following STOP
resistance measurements:
· Terminal P2-72 (+5 V Supply) and all the other terminals on the
P2 connector
· Terminal P2-72 and the engine ground.
E. For the engine oil pressure sensor, perform the following re-
sistance measurements:
· Terminal P2-80 (+5 V Supply) and all the other terminals on the
P2 connector
· Terminal P2-80 and the engine ground.
5. Check the +5 V Supply and the Sensor Common for an Less than Result: At least one resistance measurement is greater
Open Circuit 10 Ohms than 10 Ohms. The +5 V supply wire or the return wire has
excessive resistance. There may be a problem in a
A. For the intake manifold pressure sensor, install a wire jumper connector.
between terminals P2-72 (+5 V Supply) and P2-3 (Sensor
Common). Repair: Repair the wire and/or the connector, when possi-
ble. Replace parts, if necessary. Verify that the problem is
B. For the engine oil pressure sensor, install a wire jumper be- resolved.
tween terminals P2–80 (+5 V Supply) and P2 (Sensor Common).
STOP
Note: Wiggle the harness during the following measurements to
reveal any intermittent short condition. Result: The measurement is less than 10 Ohms.
C. Measure the resistance between terminals A and B at the har- Contact the Dealer Solutions Network (DSN).
ness connector for the suspect pressure sensor.
Complete the procedure in the order in which the Note: Performing steps within this procedure
steps are listed. requires the use of a multimeter capable of
measuring a PWM duty cycle and frequency. Refer to
i06627466 Table 116 for the tools recommended for the
procedure.
Speed Control - Test

system if a problem is suspected with the circuit that
is for the throttle position sensor. Also use this
procedure if one of the diagnostic codes in Table 117
is active or easily repeated.
UENR4542-04 223
Circuit Tests
Table 116
Recommended Tools
- Digital Multimeter
CVT0019 Adapter Cable As
Table 117
Code Description
The ECM detects signal voltage that is not in the acceptable

range.
Accelerator Pedal Position #1 : Volt-
91-3 91–3 The code is logged. The ECM flags the throttle position as in-
age Above Normal
valid data and a default value is used. The engine speed is
limited to high idle.
The ECM detects signal voltage that is not in the acceptable

range.
Accelerator Pedal Position #1 : Volt-
91-4 91–4 The code is logged. The ECM flags the throttle position as in-
age Below Normal
valid data and a default value is used. The engine speed is
The ECM detects an incorrect frequency on the throttle signal

Accelerator Pedal Position #1 : Ab- or an incorrect duty cycle on the throttle signal.
91-8 91–8 normal Frequency, Pulse Width, or The code is logged. The ECM flags the throttle position as in-
Period valid data and a default value is used. The engine speed is
The ECM detects an incorrect frequency on the throttle signal

Throttle #2 Position Sensor : Abnor- or an incorrect duty cycle on the throttle signal.
- 1690–8 mal Frequency, Pulse Width, or The code is logged. The ECM flags the throttle position as in-
Period valid data and a default value is used. The engine speed is
The throttle position sensor is mounted to a pedal

assembly that allows the operator to control the
speed of the engine. The geometry of the pedal
assembly controls both the travel of the sensor and
the range of the output signal. The throttle position
sensor cannot be adjusted.
The output from the throttle position sensor is a PWM
signal that varies with the position of the throttle
pedal. The throttle position sensor produces a
minimum duty cycle in the released position and a
maximum duty cycle in the fully depressed position.
When the pedal is released, the ECM translates the
sensor output signal to a throttle position of 0
percent. When the pedal is fully depressed, the ECM
translates the output signal to a throttle position of
100 percent.
224 UENR4542-04
Circuit Tests
Table 118
1. Check the Signal Frequency and the Duty Cycle at the Frequency Result: The frequency and the duty cycle are within specifi-
Sensor cations for the entire range of the pedal.
Duty cycle
A. Turn the keyswitch to the OFF position. Repair: Repair the harness or replace the harness. Verify
that the problem is resolved.
B. Remove the wire from terminal location C (throttle position) on
the harness side of the connector for the throttle position sensor. Result: The ECM detects an incorrect frequency on the
throttle signal or an incorrect duty cycle on the throttle signal.
C. Install a CVT0019 Adapter Cable As (3-PIN BREAKOUT) at The frequency is below 150 Hz or the frequency is above
the connector for the throttle position sensor. 1000 Hz. The duty cycle is less than 5 percent or the duty
cycle is greater than 95 percent.
D. Connect the connector for the throttle position sensor.
F. Measure the frequency and the duty cycle between terminal B

(digital return) and terminal C (throttle position) at the CVT0019
Adapter Cable As (3-PIN BREAKOUT). Operate the throttle pedal
whilst making the measurements.
Turn the keyswitch to the OFF position.
Remove the breakout harness. Restore the wiring for the harness
connector to the original configuration.
2. Check the Supply Voltage to the Sensor 7.5 VDC Result: The supply voltage is above 7.5 VDC at the sensor
connector.
A. Turn the keyswitch to the OFF position. The wiring is OK.
B. Disconnect the harness connector for the throttle position Repair: Replace the sensor. Verify that the problem is
sensor. resolved.
C. Measure the voltage across terminal A (8 V supply) and termi- Result: The supply voltage is not above 7.5 VDC at the sen-
nal B (digital return) on the harness side of the connector. sor connector.
The supply voltage is not reaching the speed control.
Repair: Repair the harness wiring or replace the harness.

Verify that the problem is resolved.

steps are listed.
i06627528
Speed/Timing - Test

system if a problem is suspected with the primary
engine speed/timing sensor. Also use this procedure
if a problem is suspected with the secondary engine
speed/timing sensor. Use this procedure to
troubleshoot the electrical system if a diagnostic code
in Table 119 is active or easily repeated.
UENR4542-04 225
Circuit Tests
Table 119
The code is logged. The Electronic Control Module (ECM) can

default to the secondary engine speed/timing sensor. The de-
Engine Speed : Abnormal Frequency, Pulse fault will occur if a valid signal is not received from the primary
190-8 190–8
Width, or Period engine speed/timing sensor. The engine will shut down only if
the signals from the primary engine speed/timing sensor and
the secondary engine speed/timing sensor are abnormal.
The code is logged. If a valid signal is not received from the sec-
ondary engine speed/timing sensor, the ECM will default to the
Engine Speed Sensor #2 : Abnormal Fre-
723-8 342–8 primary engine speed/timing sensor. The engine will shut down
quency, Pulse Width, or Period
only if the signals from the primary engine speed/timing sensor
and the secondary engine speed/timing sensor are abnormal.
The engine uses two engine speed/timing sensors.

Both sensors detect the reference for engine speed
and timing. The ECM uses the pulses to determine
the position of the crankshaft. The ECM measures
the time between the pulses that are created by the
sensors as the gears rotate to determine rpm.
After locating the No. 1 cylinder, the ECM triggers
each injector in the correct firing order and at the
correct unit injector timing. The actual timing and
duration of each injection is based on engine rpm
and load. If the engine is running and the signal from
the primary engine speed/timing sensor is lost, a
slight change in engine performance will be noticed.
The change will be noticed when the ECM performs
the changeover to the secondary engine speed/
timing sensor. Loss of the signal from the secondary
engine speed/timing sensor during engine operation
will not result in any noticeable change in engine
performance. However, if the signal from the
secondary engine speed/timing sensor is not present
during start-up the following conditions may exist:
• The engine may require a slightly longer amount
of time to start up.
• The engine may run rough for a few seconds until
the ECM determines the proper firing order by
using the primary engine speed/timing sensor
only.
The engine will start and the engine will run when
only one sensor signal is present from either of the
sensors. Loosing the signal from both of the sensors
during engine operation will result in the termination
of injection. The ECM will then shut down the engine.
The loss of the signal from both of the sensors during
start-up will prevent the engine from starting.
Both sensors are magnetic sensors with an integral
connector. The two sensors are not interchangeable.
Do not switch the positions of the sensor. If the
sensors are replaced, a timing calibration is not
necessary for the engine.
226 UENR4542-04
Circuit Tests
Table 120
1. Check the Engine Speed/Timing Circuit Engine Result: The engine started.
starting
A. Establish communication between the electronic service tool Proceed to Test Step 2.
and the Electronic Control Module (ECM) . Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary. Result: The engine did not start.
B. Turn the keyswitch to the ON position. Proceed to Test Step 3.
C. Monitor the “Engine Starting” screen in the electronic service

tool.
Start the engine and run the engine. The problem may occur when
the engine is at any operating temperature. However, the problem
is more likely to occur when the engine is at the normal operating
temperature.
2. Check for Diagnostic Codes Diagnostic Result: There is an active diagnostic code or there is a tim-
Trouble ing pattern that is “Not Detected” .
A. With the engine running, monitor the electronic service tool for Codes
diagnostic codes. Also monitor the “Engine Starting” screen for an Proceed to Test Step 5.
engine speed/timing that is “Not Detected” .
Result: There is not an active diagnostic code and there is
B. Wait at least 30 seconds for activation of the diagnostic codes. not a timing pattern that is “Not Detected” .
Look for these codes on the electronic service tool: Return the unit to service.
190-8
723-8 (342–8)
(continued)
UENR4542-04 227
Circuit Tests
(Table 120, contd)

3. Check the Battery Voltage Battery Result: The battery voltage is OK.
voltage
A. Monitor the “Engine Starting” screen in the electronic service Proceed to Test Step 4.
tool.
Result: The battery voltage is not OK.
Monitor the battery voltage. Crank the engine for 5 seconds.
Repair: Refer to Troubleshooting, “Engine Cranks but Does
Monitor the battery voltage whilst cranking the engine. Not Start”.
4. Check the Engine Speed and the Engine Speed/Timing Crank speed Result: The sensors show an acceptable cranking speed.
Status The timing pattern shows “Detected” .
Repair: Refer to Troubleshooting, “Engine Cranks but Does
A. Monitor the “Engine Starting” screen in the electronic service Not Start”.
tool.
Result: A sensor does not show an acceptable cranking
B. Crank the engine for 5 seconds. Whilst the engine is cranking, speed and/or the timing pattern shows “Not Detected” .
verify that the sensors show an acceptable cranking speed. Proceed to Test Step 5.
C. Whilst the engine is cranking, check the status of the engine

speed/timing sensors.

Typical left side engine view
(1) Crankshaft speed/timing sensor
228 UENR4542-04
Circuit Tests
(2) Camshaft speed/timing sensor
Table 121
5. Inspect the Sensor Assembly Debris and/ Result: The sensor and the sensor assembly mounting are
or corrosion OK.
A. Turn the keyswitch to the OFF position. Mounting
bracket Proceed to Test Step 6.
B. Visually inspect the sensor and the sensor assembly without re-
moving the sensor assembly from the engine. Flanges must be Result: The sensor and/or the sensor assembly has a me-
flush against the surface of the front timing gear housing to ensure chanical problem or the harness has debris and/or
proper operation. corrosion.
C. Inspect the sensor bracket . Verify that the bracket securely Repair: Repair the sensor and/or the sensor assembly or re-
holds the flanges of the sensors flush against the engine. place the sensor and/or the sensor assembly.
Verify that the bracket is not bent. If the bracket is bent or if an ob- Replace the sensor and the sensor harness connector if
struction is preventing the sensor assembly from being installed there was debris and/or corrosion. Verify that the problem is
correctly, the engine will not start. resolved.
Disconnect the harness from the speed/timing sensors. Check the

harness for debris and for corrosion.
Perform a 45 N (10 lb) pull test on the harness wiring.

UENR4542-04 229
Circuit Tests

Terminal locations at the connector for the speed/
timing sensors
(1) Engine speed/timing signal (−)
(2) Engine speed/timing signal (+)
Table 122
6. Use a Multimeter to Check the Harness Wiring 3.0 ± 0.2 Result: The voltage was OK for all the measurements.
VDC
A. Turn the keyswitch to the ON position. Proceed to Test Step 7.
B. Perform the following procedure for each sensor. Result: The voltage was not OK for at least one of the
measurements.
1. Measure the voltage between terminal 1 and a good engine There is a problem in the harness wiring.
ground. The voltage is 3.0 ± 0.2 VDC.
Repair: Repair the appropriate harness wiring or replace the
2. Measure the voltage between terminal 2 and a good engine appropriate harness. Verify that the problem is resolved.
ground. The voltage is 3.0 ± 0.2 VDC.
7. Measure the Resistance of the Sensor 75 Ohms to Result: The resistance measurement for the sensor is within
230 Ohms the specification. There is no damage to the sensor tip.
A. Turn the keyswitch to the OFF position. primary
sensor Repair: If the engine was running before removing the sen-
B. Disconnect the engine harness from the sensor. sor, reinstall the sensor.
600 Ohms to
C. Remove the sensor. Check the sensor tip for any damage. 1800 Ohms Use the electronic service tool to check for any active diag-
secondary nostic codes. Troubleshoot any active diagnostic codes.
D. For the primary engine speed/timing sensor, measure the re- sensor
sistance between terminal 2 (Primary engine speed/timing +) to If the engine was not running before removing the sensor,
terminal 1 (Primary engine speed/timing −). Resistance values refer to Troubleshooting, “Engine Cranks but Does Not
should be 75 Ohms to 230 Ohms. Start”.
E. For the secondary engine speed/timing sensor, measure the re- Result: The resistance measurement for the sensor is within
sistance between terminal 2 (secondary engine speed/timing +) to the specification. There is damage to the sensor tip.
terminal 1 (secondary engine speed/timing −). Resistance values
should be 600 Ohms to 1800 Ohms. Repair: Inspect the housing for a cause of the sensor dam-
age. Make any necessary repairs.
F. Turn the keyswitch to the ON position.
Replace the sensor assembly. Verify that the problem is
G. Check for -13 codes. Wait at least 30 seconds in order for the resolved.
diagnostic codes to become active.
Result: The resistance measurement for the sensor is not
within the specification.
Repair: Replace the sensor assembly.

steps are listed.
230 UENR4542-04
Service
Service • Clear event codes. Most event codes require the

use of factory passwords to clear the code once
the code has been logged. Clear these codes only
when you are certain that the problem has been
corrected.
i06273960
• Unlock parameters. Factory passwords are
Customer Passwords required in order to unlock certain system
configuration parameters. Refer to
Troubleshooting, “Configuration Parameters”.
Customer passwords may be used to protect Since factory passwords contain alphabetic
customer parameters from being changed. The characters, the electronic service tool must be used
electronic service tool can be used to change certain to perform these functions. In order to obtain factory
parameters. There are some parameters that cannot passwords, proceed as if you already have the
be changed and there are some applications that do password. If factory passwords are needed, the
not allow any changes to the programmable electronic service tool will request the factory
monitoring system. The passwords are programmed passwords. The electronic service tool will display the
into the Electronic Control Module (ECM) with the information that is required to obtain the passwords.
electronic service tool. One password may be
programmed or both passwords may be i06274006
programmed. If customer passwords are not
programmed, customer parameters may be changed
by anyone.
ECM Will Not Accept Factory
To obtain customer passwords, contact the owner of Passwords
the engine. If the owner has forgotten the customer
passwords, factory passwords are used to create
temporary customer passwords. Temporary
customer passwords can be used to change the Probable Causes
original customer passwords or any parameter that is
protected by a customer password. When the • Incorrect information for the password request
electronic service tool is disconnected, you will be
prompted to restore the original customer passwords. • Incorrect passwords
If the original passwords are not restored, the
passwords will be changed to the temporary Recommended Actions
passwords.
Check the Information for the Password
i05969825
Request
Factory Passwords
The information for the password request must be
obtained from the Engine Control Module (ECM) that
is being programmed. Do not use information from an
old ECM in order to program factory passwords on a
NOTICE replacement ECM.
Operating the engine with a flash file not designed for
that engine will damage the engine. Be sure the flash Verify that the information used to request that the
file is correct for your engine. password is identical to the information that is
displayed on the electronic service tool.
Note: Factory passwords are provided only to Engine Serial Number – The engine serial number
Perkins distributors. must be from the electronic service tool screen rather
than the engine information plate.
Factory passwords are required to perform each of
the following functions: Reason Code – Use the reason code from the
factory password screen. Reason codes are
• Program a new Electronic Control Module (ECM). assigned for specific purposes and reason codes are
When an ECM is replaced, the system not interchangeable.
configuration parameters must be programmed
into the new ECM. A new ECM will allow these Turn the key to the OFF position. Then, turn the
parameters to be programmed once without keyswitch to the ON position. Try to enter the
factory passwords. After the initial programming, passwords again.
some parameters are protected by factory
passwords.
UENR4542-04 231
Service
Incorrect Passwords
Verify that the correct passwords were entered.
Check each character in each password.
If rechecking the passwords does not correct the
problem, change a customer parameter. Change the
parameter from the current value to another value
and then change the customer parameter back to the
original value. The sequence of events will change
the total tattletale. The new total tattletale will require
obtaining new factory passwords. Obtain new factory
passwords and enter the passwords.
i06275670
Electronic Service Tool Does

Not Communicate
Use this procedure to solve communication problems

between the electronic service tool and the engine
control module (ECM). The electronic service tool
must communicate with the ECM on the J1939 data
link in order to service the engine.
Indicators on the communication adapter indicate
that communication is occurring on a particular data
link. The “J1939 / DeviceNet” indicator indicates that
the communication adapter is communicating on the
J1939 data link. The electronic service tool displays a
message during the connection if electronic service
tool cannot communicate on both data links.
The following conditions can cause a communication
problem:
• Incorrect communication adapter

• Use of a parallel cable between the
communication adapter and the PC
• Incorrect version of electronic service tool
• Incorrect firmware in the communication adapter

• Incorrect configuration of the electronic service
tool
• A problem with electrical power to the

communication adapter
• A problem with electrical power to the engine ECM

• A problem with the wiring for a data link
• A problem with the electrical cables between the

PC and the vehicle
232 UENR4542-04
Service
Table 123
1. Determine the Problem Communication Result: Both indicators on the communication adapter
problem are not flashing.
A. Determine the communication problem.
If an indicator other than the “POWER” indicator is illuminated Proceed to Test Step 2.
when electronic service tool is not communicating with an
ECM, disconnect and reconnect the communication adapter. Result: The electronic service tool indicates that the en-
gine is serviced on the J1939 data link.
Result: The electronic service tool displays a message

that indicates the firmware in the communication adapt-
er does not support communication on the data link.
Result: The electronic service tool displays an Error “

#142 The interface hardware is not responding”
message.
Result: The electronic service tool displays a message

that indicates that the electronic service tool cannot find
an exact match for the software version in the ECM.
Repair: Update the electronic service tool to the latest

available version.
Result: The power indicator is not illuminated.
2. Verify that the Correct Communication Adapter is Being Communication Result: An incorrect communication adapter is being
Used adapter used.
A. A 27610401 Communication Adapter Gp must be used to Repair: Connect a correct communication adapter. Re-
communicate. fer to Troubleshooting, “Electronic Service Tools”, if
necessary.
B. Determine the communication adapter that is being used.
Attempt to establish communication. Continue with this
procedure if the communication adapter does not com-
municate on the data link.
Result: A correct communication adapter is being used.

However, the “Power” indicator is not illuminated.
Result: A correct communication adapter is being used.

The “Power” indicator is illuminated.
(continued)
UENR4542-04 233
Service
(Table 123, contd)

3. Check the Version of the Firmware for the Communica- Firmware Result: The electronic service tool communicates on
tion Adapter both data links.
The version of the firmware for the communication adapter The problem is resolved.
must be the latest available.
Result: The electronic service tool does not communi-
A. Electronically disconnect the electronic service tool. Verify cate on both data links.
that the “power” indicator on the communication adapter is
illuminated. Proceed to Test Step 4.
B. Click on the “Utilities” menu.
C. Click on the “Comm Adapter III Toolkit” menu.
D. Wait for the tool kit to open. Then, click the “Utilities” menu.
E. Click “Application Firmware Flash” .
F. Select the latest “.apf” file from the list.
G. Click “OK” . Then, click “Begin Flash” .
H. Wait for the “Flashes Completed Successfully” message to

appear.
I. Attempt to connect the electronic service tool.
4. Verify that the Electronic Service Tool is Configured Configured correctly Result: The electronic service tool communicates on
Correctly the data link.
The electronic service tool must be configured correctly in order The problem is resolved.
to communicate on both data links.
A. Click on the “Utilities” menu. cate on both data links. The “POWER” indicator is not
illuminated.
B. Click on the “Preferences” menu.
C. Select the “Communications” tab.
D. Verify that “Communication Adapter III (Serial IP)” is cate on both data links. The “POWER” indicator is
selected. illuminated.
If “Communication Adapter III (Serial IP)” is not an option for se- Proceed to Test Step 6.
lection, the version of the electronic service tool is incorrect.
Update the version of the electronic service tool. Then, perform

this Test Step again.
E. Verify that the port is correct.
F. Verify that the “Enable Dual Data Link Service” option is

checked.
G. Click “OK” . The electronic service tool must reconnect in or-

der for any changes to be used.
(continued)
234 UENR4542-04
Service
(Table 123, contd)

H. Electronically disconnect the electronic service tool if
changes are made to any of the settings for communications.
Electronically connect the electronic service tool. Attempt to es-
tablish communication. Observe the indicators on the commu-
nication adapter.
A “limited support” warning should not be displayed. The

“J1939 / DeviceNet” indicator should be flashing. The indicator
indicates that the electronic service tool is communicating on
both data links.

Power terminals at the service tool connector
(Terminal A) +Battery
(Terminal B) −Battery
UENR4542-04 235
Service
Table 124
5. Check the Electrical Power to the Communication Adapter Electrical Result: Battery voltage is not present at the service tool
power connector.
A. Check for battery voltage at the service tool connector.
Repair: Inspect the vehicles wiring and fuses. Determine
the cause of the missing voltage. Make the necessary
repairs.
Attempt to establish communication after the electrical

power is at the service tool connector.
Proceed to Test Step 6 if the service tool does not communi-

cate on both data links.
Result: The electronic service tool indicates that the engine

is serviced on the data link.
Repair: Verify that the cable between the service tool con-
nector and the communication adapter is OK. Replace the
cable, if necessary.
Replace the communication adapter if the following condi-

tions are true:
1. There is power at the cables “DATA LINK” connector.
2. The communication adapters “POWER” indicator is not

illuminated.
236 UENR4542-04
Service

General information about the electrical power to the ECM
UENR4542-04 237
Service
Table 125
6. Check the Electrical Power to the ECM Electrical Result: Battery voltage is missing from a P1 terminal.
power
A. Verify that the keyswitch is ON. Inspect the application wiring and fuses. Determine the
cause of the missing voltage. Make the necessary repairs.
B. Refer to Illustration 114 . Verify that battery voltage is present at
the terminals that are indicated in the Illustration. Be sure to con- Attempt to establish communication after the electrical
nect the voltmeter between the “UNSWITCHED +BATTERY” termi- power is at all of the appropriate P1 terminals. Continue with
nals and the “-BATTERY” terminals. this procedure, if necessary.
C. Verify that battery voltage is present at P1-70. Result: Battery voltage is present at all of the appropriate
P1 terminals.
Proceed to the Test Step 7
7. Try to Establish Communication With a Bypass Harness Harness Result: The electronic service tool communicates on the da-
ta link when the bypass harness is used. There is a problem
A. Connect the communication adapter to the engine ECM with a with the wiring.
2900A038 Wiring Harness (ECM BYPASS) and a T400926 Har-
ness (ELECTRONIC CONTROL MODULE). Repair: Repair the data link. Refer to Troubleshooting, “Data
Link - Test”.
B. Attempt to establish communication.
i06275076 5. Start the “Test ECM Mode” on the electronic

service tool. Access the feature through the
Test ECM Mode “Service” menu. The electronic service tool will
display the status of the test ECM and the hours
that are remaining for the “Test ECM Mode” .
“Test ECM Mode” is a feature in the software that can
be used to help troubleshoot an engine that may Note: “Test ECM Mode” can only be activated if the
have a fault in the Electronic Control Module (ECM). engine serial number has not already been
This feature allows a standard ECM to be used as a programmed during normal operation of the ECM. If
test ECM. This feature eliminates the need to stock a the engine serial number is programmed and the
test ECM. ECM is not in “Test ECM Mode” , the ECM can never
be used as a test ECM.
1. Search for the latest flash file for the engine.
Note: If a newer software version is available for the 6. Use the “Copy Configuration” feature on the
engine, install the newest software on the suspect electronic service tool to program the test ECM.
ECM. If the new software does not eliminate the fault,
Note: If the “ECM Replacement” feature cannot be
continue with this procedure.
used, program the test ECM with the values from the
2. Use the “Copy Configuration” feature on the “Parameters Worksheet” and the values from the
Configuration Parameters.
electronic service tool to copy the parameters from
the suspect ECM. 7. Program the engine serial number into the test
Note: If the “ECM Replacement” feature cannot be ECM.
used, record the programmed values into the Note: The “Test ECM Mode” must be activated
“Parameters Worksheet” . Also record the system before the engine serial number is programmed into
configuration parameters. the ECM.
3. Disconnect the suspect ECM. Temporarily connect 8. Verify that the test ECM eliminates the fault.
the test ECM to the engine. Do not mount the test
ECM on the engine.
4. Flash program the test ECM with the newest
software that is available.
238 UENR4542-04
Service
When the “Test ECM Mode” is activated, an internal Exchanging injectors can help determine if a
timer sets a 24 hour clock. This clock will count down combustion problem is in the injector or in the
only while the ECM is powered and the keyswitch is cylinder. If two injectors that are currently installed in
in the ON position. After the ECM has counted down the engine are exchanged between cylinders, the
the 24 hour period, the ECM will exit the “Test ECM injector trim files can also be exchanged. Press the
Mode” . The parameters and the engine serial “Exchange” button at the bottom of the “Injector Trim
number will be set. Calibration” screen on the electronic service tool.
Select the two injectors that have been exchanged
If the test ECM eliminates the fault, the engine can be and press the “OK” button. The tattletale for the
released while the “Test ECM Mode” is still active. injectors that were exchanged will increase by one.
Once an ECM has been activated in the “Test ECM 1. Perform the following procedure to download an
Mode” , the ECM will stay in the “Test ECM Mode”
until the timer times out. Anytime prior to the “Test injector trim file from PTMI. Otherwise, use the
ECM Mode” timing out, the “Test ECM Mode” can be injector trim file from the CD-ROM that is
reset to 24 hours. packaged with the injector.
If the ECM is used as a test ECM for more than one Note: The injector serial number and the injector
engine, reactivate the “Test ECM Mode” in order to confirmation code are located on the injector.
reset the parameters to default values. Then use the
“Copy Configuration” feature to program the
parameters into the test ECM or manually program a. Record the injector serial number and the
the parameters to the correct values. injector confirmation code for each injector.
i06275078
b. Log in to the Perkins secured web site and go to
PTMI.
Injector Trim File - Install c. Click on “New Search” and select “Injector e-
trim File” from the drop-down menu.
The electronic service tool is used to load injector d. Enter the serial number for the injector in the
trim files into the Engine Control Module (ECM). search field.
Injector trim files are available from these sources:
e. Download the injector trim file to the PC. Repeat
• A CD-ROM that is packaged with each new this procedure for each injector, as required.
injector and each remanufactured injector
2. Establish communication between the electronic
• Perkins Technical Marketing Information (PTMI) service tool and the engine ECM. Refer to
Troubleshooting, “Electronic Service Tools”, if
Replacing an Injector necessary.
An injector trim file must be loaded into the ECM if an 3. Select the following menu options on the electronic
injector is replaced. service tool:
Replacing the ECM • Service
The “Copy Configuration” utility on the electronic
service tool copies the injector trim files between two • Calibrations
engine control modules. If the “Copy Configuration”
fails, load all of the injector trim files manually into the • Injector Trim Calibration
new ECM.
4. Select the appropriate cylinder.
“Injector Trim” is displayed below a 630-2
Programmed Parameter Fault : Erratic, Intermittent, 5. Click on the “Change” button.
or Incorrect. The diagnostic code is displayed on the 6. Select the appropriate injector trim file from the PC
or the CD-ROM.
Exchanging Injectors
7. Click on the “Open” button.
8. Enter the injector confirmation code.
9. Click on the “OK” button.
The injector trim file is loaded into the ECM.
UENR4542-04 239
Service
10. Repeat the procedure for each cylinder, as

required.
i05969869
ECM Software - Install

system if the diagnostic code in Table 126 is active.
Table 126
Code Description
The flash file is for a different engine family or for a differ-

ent engine application.
Personality Module : Erratic, Intermit-
631-2 253-2 The engine will not start. Clearing this diagnostic code re-
tent, or Incorrect
quires factory passwords. The personality module code
must be reset to zero.
Flash programming is a method of programming or Note: You must have the engine serial number in
updating the flash file in the engine Electronic Control order to search for the part number of the flash file.
Module (ECM). The electronic service tool is used to
flash program a file into the memory of the engine 2. Connect the electronic service tool to the
ECM. diagnostic connector.
Note: Customer versions of the electronic service 3. Turn the keyswitch to the ON position. Do not start
tool do not have the capability for flash programming. the engine.
Consult your local Perkins Distributor for assistance.
4. Select “WinFlash” from the “Utilities” menu on the
The engine is equipped with an Electronic Control electronic service tool.
Module (ECM). The ECM contains no moving parts.
Follow the troubleshooting procedures in this manual Note: If “WinFlash” will not communicate with the
in order to be sure that replacing the ECM will correct ECM, refer to Troubleshooting, “Electronic Service
the problem. Verify that the suspect ECM is the Tool Does Not Communicate”.
cause of the problem.
5. Flash program the flash file into the ECM.
Note: Ensure that the ECM is receiving power and
that the ECM is properly grounded before a. Select the engine ECM under the “Detected
replacement of the ECM is attempted. Refer to the ECMs” .
schematic diagram.
b. Press the “Browse” button in order to select the
Use the electronic service tool to read the part number of the flash file that will be
parameters in the suspect ECM. Record the
parameters in the suspect ECM. Install the flash file programmed into the ECM.
into the new ECM. After the ECM is installed on the
engine, the parameters must be programmed into the c. When the correct flash file is selected, press the
new ECM. “Open” button.
NOTICE d. Verify that the “File Values” match the

If the flash file and engine application are not application. If the “File Values” do not match the
matched, engine damage may result. application, search for the correct flash file.
Perform the following procedure in order to replace e. When the correct flash file is selected, press the
the ECM. “Begin Flash” button.
1. Obtain the part number for the new flash file. f. The electronic service tool will indicate when
flash programming has been successfully
Note: If you do not have the part number for the flash completed.
file, use “PTMI” on the Perkins secured web site.
240 UENR4542-04
Service
6. Access the “Configuration” screen under the Note: If the “Copy Configuration” process fails and
“Service” menu in order to determine the the parameters are not obtained in Step 1.b, the
parameters that require programming. parameters must be obtained elsewhere. Some of
the system configuration parameters are stamped
7. Start the engine and check for proper operation. on the engine information plate. Most of the
Check that there are no active diagnostic codes. parameters must be obtained from the factory.
Parameters that are related to customer specified
i05969942 parameters must be obtained from the customer or
from the Original Equipment Manufacturer (OEM).
ECM - Replace 2. Remove the ECM:
a. Turn the keyswitch OFF.
The Engine Control Module (ECM) contains no
moving parts. Replacement of the ECM can be b. Disconnect the P1 and P2 connectors.
costly. Replacement can also be a time consuming
task. Follow the troubleshooting procedures in this c. Disconnect the ECM ground strap.
manual in order to ensure that replacing the ECM will
correct the problem. Verify that the suspect ECM is d. Remove the mounting hardware at each corner
the cause of the problem. of the ECM.
3. Install the replacement ECM:
NOTICE
If the flash file and engine application are not
matched, engine damage may result. a. Use the old mounting hardware to install the
replacement ECM.
Perform the following procedure in order to replace b. Connect the ECM ground strap.
the ECM:
c. Connect the P1 and P2 connectors. Refer to
1. Record the configuration data: Troubleshooting, “Electrical Connectors -
Inspect” for the correct torque values.
a. Try to establish communication between the
electronic service tool and the ECM. Proceed to 4. Configure the replacement ECM:
Test Step 2 if the electronic service tool does not
communicate with the ECM. a. Flash program the latest available flash file into
the ECM. Refer to Troubleshooting, “ECM
b. Print the parameters from the “Configuration” Software - Install” for the correct procedure.
screen on the electronic service tool. If a printer
is unavailable, record all of the parameters. b. Use the electronic service tool to match the
engine application and the interlock code if the
c. Obtain the customer passwords from the replacement ECM was used for a different
vehicle owner. Access the customer specified application.
parameters with the electronic service tool.
Record the value of each customer parameter. c. If the “Copy Configuration” process from Step 1.
b was successful, return to the “Copy
• Record ECM lifetime Configuration/ECM Replacement” screen on the
totals. electronic service tool and select “Program
ECM” . Proceed to Step 4.e when programming
• Record any logged diagnostic codes.
is complete.
d. If the “Copy Configuration” process from Step 1.

Note: If the customer passwords are not available
proceed to Troubleshooting, “Customer b was unsuccessful, manually program the ECM
Passwords” for details that are related to customer parameters. The parameters must match the
passwords. parameters from Step 1.b.
e. Program the engine monitoring system, if

d. Use the “Copy Configuration/ECM
necessary.
Replacement” feature that is found under the
“Service” menu on the electronic service tool. f. Calibrate the engine speed/timing if there is a
Select “Load from ECM” in order to copy the diagnostic code for speed/timing sensor
configuration data from the suspect ECM. calibration. The procedure is in Troubleshooting,
“Timing - Calibrate”.
UENR4542-04 241
Service
Note: Use the electronic service tool to perform the Check Connectors for Moisture
“fuel system functional test” . This test established
a baseline value of the fuel system rate of fuel
and Corrosion
return at high rail pressure. Other diagnostic codes
may be activated if this test is not performed.
i05969972
Electrical Connectors - Inspect
Most electrical faults are caused by poor

connections. The following procedure will assist in
detecting faults with connectors and with wiring. If a
fault is found, correct the condition and verify that the
fault is resolved.
Intermittent electrical faults are sometimes resolved
by disconnecting and reconnecting connectors.
Check for diagnostic codes immediately before you
disconnect a connector. Also check for diagnostic
codes after you reconnect the connector. If the status
of a diagnostic code is changed due to disconnecting
and reconnecting a connector, there are several
possible reasons. The likely reasons are loose
terminals, improperly crimped terminals, moisture, Illustration 115 g01131211
corrosion, and inadequate mating of a connection. Detail A illustrates the incorrect angle of wire entry
into the connector. The wire should enter the
Follow these guidelines: connector at a perpendicular angle. (typical example)
• Always use a CH11155 Crimp Tool to service Inspect all the harnesses. Ensure that the routing of
Deutsch HD and DT connectors. Never solder the the wiring harness allows the wires to enter the face
terminals onto the wires. of each connector at a perpendicular angle.
Otherwise, the wire will deform the seal bore. The
• Always use a 28170079 Wedge Removal Tool in damaged seal will create a path for the entrance of
order to remove wedges from DT connectors. moisture. Verify that the seals for the wires are
Never use a screwdriver to pry a wedge from a sealing correctly.
connector.
• Always use a breakout harness for a voltmeter

probe or a test light. Never break the insulation of
a wire in order to access to a circuit for
measurements.
• If a wire is cut, always install a new terminal for the
repair.
• Determine if the problem is intermittent. If the

problem is intermittent, attempt to test the circuit
before you disconnect any electrical connectors.
The test will help identify the root cause of
intermittent problems. The “Wiggle Test” on the
electronic service tool may be able to test the
circuit. Refer to the documentation that
accompanies the electronic service tool. Perform
the wiggle test on the circuit, when possible.
Otherwise, continue with this procedure.
242 UENR4542-04
Service

Diagram for the installation of a connector plug Seal for the ECM connector (typical example)
(typical example)
(1) Electronic Control Module (ECM) connector Disconnect the suspect connector and inspect the
(2) Correctly inserted plug connector seal. Ensure that the seal is in good
(3) Incorrectly inserted plug condition. If necessary, replace the connector.
Ensure that the sealing plugs are in place. If any of Thoroughly inspect the connectors for evidence of
the plugs are missing, replace the plug. Ensure that moisture entry.
the plugs are inserted correctly into the connector.
Note: Some minor seal abrasion on connector seals
is normal. Minor seal abrasion will not allow the entry
of moisture.
If moisture or corrosion is evident in the connector,
the source of the moisture entry must be found. The
source of the moisture entry must be repaired. If the
source of the moisture entry is not repaired, the fault
will recur. Simply drying the connector will not fix the
fault. Check the following items for the possible
moisture entry path:
• Missing seals
• Incorrectly installed seals
• Nicks in exposed insulation

Seal for a three-pin connector (typical example) • Improperly mated connectors
Moisture can also travel to a connector through the
inside of a wire. If moisture is found in a connector,
thoroughly check the connector harness for damage.
Also check other connectors that share the harness
for moisture.
Check the Wires for Damage to the

Insulation
Carefully inspect each wire for signs of abrasion,
nicks, and cuts.
Inspect the wires for the following conditions:
UENR4542-04 243
Service
• Exposed insulation Check Individual Pin Retention into

• Rubbing of a wire against the engine the Socket
• Rubbing of a wire against a sharp point
Check all of the fasteners for the harness and the
ECM in order to verify that the harness is correctly
secured. Also check all of the fasteners in order to
verify that the harness is not compressed. Pull back
the harness sleeves in order to check for a flattened
portion of wire. A fastener that has been
overtightened flattens the harness. This damages the
wires that are inside the harness.
Inspect the Connector Terminals

Visually inspect each terminal in the connector. Verify
that the terminals are not damaged. Verify that the
terminals are correctly aligned in the connector and
verify that the terminals are correctly located in the Illustration 120 g01131604
connector. Diagram for testing pin retention (typical example)
Perform a Pull Test on Each Wire Verify that the sockets provide good retention for the
Terminal Connection pins. Insert a new pin into each socket one at a time
in order to check for a good grip on the pin by the
socket.
Check the Locking Mechanism of

the Connectors
Ensure that the connectors lock correctly. After you
lock the connectors, ensure that the two halves
cannot be pulled apart.
Verify that the latch tab of the connector is correctly
latched. Also verify that the latch tab of the connector
returns to the locked position.
Check the Allen Head Screws on

the Connectors
Illustration 119 g01131435 Visually inspect the allen head screws for the ECM
Receptacle lock wedge (typical example) connectors. Ensure that the threads on each allen
head screw are not damaged.
Ensure that the locking wedge for the connector is
installed correctly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed correctly.
Perform the 45 N (10 lb) pull test on each wire. Each
terminal and each connector should easily withstand
45 N (10 lb) of tension and each wire should remain
in the connector body. This test checks whether the
wire was correctly crimped in the terminal and
whether the terminal was correctly inserted into the
connector.

Allen head screw for the 120 pin ECM connector
(typical example)
244 UENR4542-04
Service
Torque the allen head bolt for the 120 pin ECM If an intermittent fault exists, the status will be
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). highlighted and an audible beep will be heard.
i06628550
Timing - Calibrate
Use this procedure if the diagnostic code in

Table 127 is active.

Allen head screw for the 70 pin ECM connector
(typical example)
Torque the allen head screw for the 70 pin ECM

connector to 6.0 + 1.5 - 1.0 N·m (55 + 13 - 9 lb in).

Allen head screw for the 40 pin customer connector
and the 70 pin customer connector (typical example)
Torque the allen head screw for the 40 pin customer

connector and the 70 pin customer connector to
2.25 ± 0.25 N·m (20 ± 2 lb in).
Perform the Wiggle Test on the

electronic service tool
Select the “Wiggle Test” from the diagnostic tests on
Choose the appropriate group of parameters to
monitor.
Press the “Start” button. Wiggle the wiring harness in
order to reproduce intermittent faults.
UENR4542-04 245
Service
Table 127

The wiring to the sensors has the wrong
637-11 261–11 Engine Timing Sensor : Other Failure Mode
polarity.
A timing calibration is required for a new

engine, replacing an Electronic Control
637-13 261–13 Engine Timing Sensor : Out of Calibration Module (ECM) that fails to communicate or
following work on the front gear train, the
camshaft, or the crankshaft.
If a 637-11 diagnostic code is active, verify that the

wiring is installed correctly to the engine speed/timing
sensors.
The ECM can calibrate the mechanical differences
between the Top Center (TC) of the flywheel and the
TC of the timing gear on the camshaft. A transducer
signals the TC of the flywheel to the ECM when a
notch on a counterweight passes by the transducer.
The engine speed/timing sensor signals the TC of the
timing gear to the ECM. Any offset between the TC of
the flywheel and the TC of the timing gear is stored
into the memory of the ECM.
Note: A timing calibration will not increase the
available engine power.
Table 128 lists the special tools that are required to
perform this procedure.
Table 128
Required Special Tools
GE50039 Transducer Adapter
GE50038 Transducer
GE50040 Cable as
T400930 Harness (1)

(1) This item is not required if the engine harness has a connector Illustration 124 g03048383
for timing calibration. (A) Timing mark
(B) Idler gear
Table 129
Crankshaft Rotation
Engine Model Number of Degrees Direction of Rotation
2206D 75 Normal Rotation
2506 60 Opposite Normal Rotation
2806D 30 Opposite Normal Rotation

246 UENR4542-04
Service
Table 130
Location of the Timing Calibration Port
Engine Model Crankshaft Counterweight Engine Location

2206D 8 Left Side
2506 2 Left Side
2806D 2 Left Side
Table 131
1. Install the Transducer Adapter Transducer Result: The transducer adapter was installed.
adapter
A. Remove the electrical power from the ECM. Proceed to Test Step 2.
B. Use the appropriate engine turning tool to put either the No. 1
piston or the No. 6 piston at the top center. Refer to Systems Opera-
tion, Testing and Adjusting.
C. Refer to Table 129 . After the top center position has been lo-
cated, rotate the crankshaft for the number of degrees that is appli-
cable to the engine model. Be sure to rotate the crankshaft in the
direction of rotation that is specified in Table 129 .
D. Refer to Table 130 . Locate the engine timing calibration port.
E. Remove the plug from the timing calibration port.
F. Thread the transducer adapter into the port
2. Install the Transducer Transducer Result: The transducer was installed.
If the crankshaft is not in the correct position when the trans- Proceed to Test Step 3.
ducer is installed, the transducer will be damaged when the en-
gine is started.
A. Apply clean engine oil to a T400931 O-Ring Seal. Install the O-

ring seal on the end of the GE50038 Transducer.
B. Push the transducer through the transducer adapter until the

transducer contacts the crankshaft counterweight.
C. Withdraw the transducer 1.0 mm (0.04 inch) and hand tighten

the nut on the adapter sleeve to secure the transducer. Move the O-
ring seal against the adapter.
UENR4542-04 247
Service

Engine Control Module
Table 132
Terminal Locations for Connection of the T400930 Harness
ECM Type ADEM 4
Connector P2 P1
Timing Calibration + 26 24
(White)
(Terminal 1) Location
Timing Calibration - 36 25
(Yellow)
(Terminal 2) Location
248 UENR4542-04
Service
Table 133
3. Connect the GE50040 Cable as Wiring Result: The wiring is installed correctly.
A. If the engine harness is equipped with a connector for timing cali- Proceed to Test Step 4.
bration, connect the GE50040 Cable as to the connector for timing
calibration and to the transducer.
B. If the engine harness is not equipped with a connector for timing

calibration, or the connector is not easily accessible, a connector
can be installed. The connector can be installed on either ECM
connector.
C. Refer to Illustration 125 to determine the type of engine ECM. Al-

so, determine the ECM connector that is easily accessible.
D. Refer to Table 132 to determine the proper terminal locations for

the connector that is easily accessible.
E. Remove the sealing plugs from the appropriate terminals. Do not

discard the sealing plugs. The sealing plugs may be reinstalled
when the timing calibration is complete.
F. Install the WH(White)wire of the T400930 Harness into the ap-

propriate location.
G. Install the YL(Yellow)wire of the T400930 Harness into the ap-

propriate location. Disregard the pin-outs on the label of the
harness.
H. Ensure that each wire is installed into the correct location. The
timing calibration will not be successful if the wires are installed
incorrectly.
4. Check for Diagnostic Codes Diagnostic Result: There are active codes other than a 637-13 di-
codes agnostic code.
A. Connect the electronic service tool to the service tool connector.
Refer to Troubleshooting, “Electronic Service Tools”. Troubleshoot the active diagnostic other than the 637-
13 diagnostic codes.
B. Start the engine and run the engine until the engine is at the nor-
mal operating temperature. Result: There are no active codes other than a 637-13
diagnostic code.
C. Check for active diagnostic codes. Wait at least 30 seconds in or-
der for the codes to become active. Proceed to Test Step 5.
The engine must not have any active diagnostic codes during
the timing calibration except for a 637-13 diagnostic code.
UENR4542-04 249
Service
Table 134
5. Calibrate the Timing Timing Result: The timing calibration was successful.
calibration
A. After the engine has warmed up, access the “Timing Calibration” Return the unit to service.
screen on the electronic service tool. Access the following display
screens in order: Result: The timing calibration was not successful.
· Service The following conditions can cause the timing calibra-

tion to fail:
· Calibrations
1. The crankshaft and camshaft gears have been reas-
· Timing Calibration sembled incorrectly.
B. Set the engine speed to 1100 ± 50 rpm. The engine speed must 2. The timing calibration probe is not installed correctly.
be steady within this rpm range in order for the calibration to be
successful. 3. The engine speed is not correct and the engine
speed is unstable. If the engine speed is unstable, refer
C. To calibrate the timing, select “Continue” on the electronic service to Troubleshooting, “Engine Misfires, Runs Rough, or Is
tool. Wait until the electronic service tool indicates that the timing is Unstable”.
calibrated.
4. There is a problem with the transducer or with the ca-
D. Perform the following procedure if the electronic service tool indi- bles. Obtain a new transducer and/or a new cable and
cates that the timing is calibrated: repeat the timing calibration.
1. Set the engine speed to low idle. 5. There is an active 190-8 code or an active 723-8
code. Troubleshoot the active codes before calibration.
2. Disconnect the GE50040 Cable as before you exit the “Timing
Calibration” screen. Otherwise, diagnostic codes may be activated. Correct any of the above conditions and repeat the cali-
bration procedure.
3. Exit the “Timing Calibration” screen on the electronic service tool.
5. Remove the transducer and remove the transducer adapter.
6. Install the plug into the timing calibration port.
7. If you installed a T400930 Harness, remove the harness or per-

manently install the harness for future use. If the harness is re-
moved, install the sealing plugs into the unused cavities of the ECM
connector. Otherwise, moisture and debris will enter the connector.
8. If the harness is permanently installed, fasten the harness to the

existing engine wiring harness with cable ties. Also, install a
T400932 Receptacle and two 2900A011 Seal Plugs on the P400
timing calibration probe connector to prevent moisture and debris
from entering the connector.

steps are listed.
250 UENR4542-04
Index Section
Index
A ECM Does Not Communicate with Other
Modules............................................................60
Acceleration Is Poor or Throttle Response Is Probable Causes .............................................60
Poor .................................................................45 Recommended Actions ....................................60
Probable Causes .............................................45 ECM Software - Install ....................................... 239
Recommended Actions ....................................45 ECM Will Not Accept Factory Passwords ............ 230
Air Shutoff - Test................................................ 127 Probable Causes ........................................... 230
Alternator Problem ..............................................47 Recommended Actions .................................. 230
Probable Causes .............................................47 Electrical Connectors ..........................................17
Recommended Actions ....................................47 Connectors for the Electronic Control Module
(ECM) ...........................................................18
B Injector Connectors..........................................19
Sensor Connectors ..........................................19
Battery Problem ..................................................49 Electrical Connectors - Inspect ........................... 241
Probable Causes .............................................49 Check Connectors for Moisture and
Recommended Actions ....................................49 Corrosion .................................................... 241
Boost Pressure Is High ........................................49 Check Individual Pin Retention into the
Probable Causes .............................................50 Socket......................................................... 243
Recommended Actions ....................................50 Check the Allen Head Screws on the
Connectors.................................................. 243
Check the Locking Mechanism of the
C Connectors.................................................. 243
CAN Data Link - Test ......................................... 136 Check the Wires for Damage to the
Circuit Tests...................................................... 127 Insulation..................................................... 242
Component Location ........................................... 11 Inspect the Connector Terminals ..................... 243
2206D Engines................................................13 Perform a Pull Test on Each Wire Terminal
2506 and 2806D Engines .................................14 Connection .................................................. 243
Configuration Parameters ....................................22 Perform the Wiggle Test on the electronic service
Parameter Descriptions....................................22 tool ............................................................. 244
System Configuration Parameters.....................27 Electrical Power Supply - Test ............................ 152
Coolant Contains Fuel .........................................50 Electronic Service Tool Does Not Communicate .. 231
Probable Causes .............................................50 Electronic Service Tools.........................................5
Recommended Actions ....................................51 Optional Service Tools........................................6
Coolant Contains Oil ...........................................51 Perkins Electronic Service Tool ..........................6
Probable Causes .............................................51 Service Tools.....................................................5
Recommended Actions ....................................52 Electronic System Overview...................................9
Coolant Level - Test........................................... 141 Engine Cranks but Does Not Start ........................61
Coolant Level Is Low ...........................................54 Engine Does Not Crank .......................................63
Probable Causes .............................................54 Engine Has Early Wear........................................65
Recommended Actions ....................................54 Probable Causes .............................................65
Coolant Temperature Is High................................55 Recommended Actions ....................................65
Probable Causes .............................................56 Engine Has Mechanical Noise (Knock) .................67
Recommended Actions ....................................56 Probable Causes .............................................67
Cooling Fan Speed - Test................................... 146 Recommended Actions ....................................67
Customer Passwords ........................................ 230 Engine Misfires, Runs Rough or Is Unstable..........70
Cylinder Is Noisy .................................................58 Probable Causes .............................................70
Probable Causes .............................................58 Recommended Actions ....................................70
Recommended Actions ....................................58 Engine Overspeeds.............................................72
Probable Causes .............................................73
Recommended Actions ....................................73
D Engine Shutdown Occurs Intermittently.................74
Probable Causes .............................................74
Data Link - Test ................................................. 148 Recommended Actions ....................................74
Diagnostic Capabilities ........................................14 Engine Stalls at Low RPM....................................76
Diagnostic Codes.............................................14 Probable Causes .............................................76
Diagnostic Trouble Codes....................................29 Recommended Actions ....................................76
Diagnostic Trouble Codes in J1939 Order..........29 Engine Top Speed Is Not Obtained .......................78
Diagnostic Trouble Codes in Perkins Data Link Probable Causes .............................................78
(PDL) Code Order ..........................................33 Recommended Actions ....................................78
Engine Vibration Is Excessive ..............................81
Probable Causes .............................................81
E Recommended Actions ....................................82
ECM - Replace ................................................. 240 Ether Starting Aid - Test ..................................... 157
Event Codes .......................................................38
UENR4542-04 251
Index Section
Active Event Codes..........................................43 Recommended Actions .................................. 119

Clearing Event Codes ......................................44
Event Codes in J1939 Code Order ....................38
Event Codes in Perkins Data Link (PDL) Code P
Order ............................................................40 Power Is Intermittently Low or Power Cutout Is
Logged Event Codes........................................43 Intermittent...................................................... 121
Parts of the Event Code....................................42 Probable Causes ........................................... 121
Troubleshooting...............................................44 Recommended Actions .................................. 121
Exhaust Has Excessive Black Smoke ...................82 Power Take-Off - Test ........................................ 173
Probable Causes .............................................82 Programmable Parameters ..................................15
Recommended Actions ....................................83 Flash Programming..........................................16
Exhaust Has Excessive White Smoke...................84 Flash Programming a Flash File........................16
Probable Causes .............................................84 Programming Parameters ................................15
Recommended Actions ....................................84 Test ECM Mode ...............................................15
Exhaust System Contains Oil ...............................87
Probable Causes .............................................87
Recommended Actions ....................................87 R
Exhaust Temperature Is High ...............................88
Probable Causes .............................................89 Retarder - Test .................................................. 179
Recommended Actions ....................................90
S
F Sensor Calibration Required - Test ..................... 190
Factory Passwords............................................ 230 Sensor Signal (Analog, Active) - Test .................. 192
Fuel Consumption Is Excessive............................92 Sensor Signal (Analog, Passive) - Test ............... 201
Probable Causes .............................................92 Sensor Supply - Test (5V Supply) ....................... 215
Recommended Actions ....................................92 Sensor Supply - Test (8 V Supply) ...................... 209
Fuel Pressure Is High ..........................................94 Service............................................................. 230
Fuel Pressure Is Low ...........................................99 Speed Control - Test.......................................... 222
Fuel Temperature Is High................................... 103 Speed/Timing - Test .......................................... 224
Symptom Troubleshooting ...................................45
Connectors and Wiring.....................................45
G Diagnostic Codes.............................................45
Follow the Procedures......................................45
General Information ..............................................4 Gather Information ...........................................45
Application Interface ..........................................4 Verify the Problem ...........................................45
Electronic Control System ..................................4 System Overview ..................................................9
Fault Detection and Reporting.............................4 Passwords ......................................................10
Overview...........................................................4 Programmable Parameters.................................9
Troubleshooting.................................................4 System Operation ..............................................9
I T
Important Safety Information ..................................2 Table of Contents ..................................................3
Indicator Lamp - Test ......................................... 162 Test ECM Mode ................................................ 237
Injector Solenoid - Test ...................................... 165 Timing - Calibrate .............................................. 244
Injector Trim File - Install .................................... 238 Troubleshooting Section ........................................4
Inlet Air Temperature Is High .............................. 109
Probable Causes ........................................... 109
Recommended Actions .................................. 109 V
Intake Manifold Air Temperature Is High.............. 111
Introduction ..........................................................4 Valve Lash Is Excessive .................................... 124
Probable Causes ........................................... 124
Recommended Actions .................................. 124
O Valve Rotator or Spring Lock Is Free................... 125
Probable Cause............................................. 125
Oil Consumption Is Excessive ............................ 112 Recommended Actions .................................. 126
Probable Causes ........................................... 112
Oil Contains Coolant ......................................... 114 W
Probable Causes ........................................... 114
Recommended Actions .................................. 115 Welding Precaution ...............................................4
Oil Contains Fuel .............................................. 117 Wiring Information ...............................................21
Measuring Fuel Dilution.................................. 117 Harness Wire Identification ...............................21
Probable Causes ........................................... 117
Oil Pressure Is Low ........................................... 118
Probable Causes ........................................... 119
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UENR4542-04 (en-us)

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Power Is Intermittently Low or Power Cutout Is

Introduction Circuit Tests

Event Codes Service

Troubleshooting Section Fault Detection and Reporting

Electronic Control System During troubleshooting, inspect all harness

28170079 Wedge Removal Tool

T400920 Wire Removal Tool (14-GA TO 18-GA, RED)

CH11155 Crimp Tool (12−AWG TO 18−AWG)

T400922 Adapter Cable As (40-PIN BREAKOUT)

GE50037 / Adapter Cable As (70-PIN BREAKOUT)

T400924 Adapter Cable As (120-PIN BREAKOUT)

Illustration 1 g01143634 N/A Torque Wrench (capable of applying 1.5 N·m

6. Protect the wiring harnesses from welding debris

(Table 1, contd) • Programming of flash file

T400926 Harness (ENGINE ECM BYPASS)

Part Number Description

- Suitable Battery Load Tester

- Suitable Temperature Adapter

Perkins Electronic Service Tool

• Programmable parameter settings

Connecting the Electronic Service Tool

4. Place the keyswitch in the ON position. If the

Electronic System • Reduced warm-up time

Overview • Reduced white smoke

• Increased cold weather starting capability

2506 and 2806D Engines

i05957583 Event Code – An event code is generated by the

Logged Codes active but the code may become logged.

J1939 Code Code Description

· One or more of the programmable parameters have not been

Programming Parameters When the “Test ECM Mode” is activated, an internal

6. Access the “Configuration” screen under the “ WinFlash”” Error Messages

Connectors for the Electronic Control

Injector Connectors Sensor Connectors

Illustration 8 g01746753 Illustration 10 g01240891

Connector at the Injector Analog Sensor Connector (passive)

Connectors for the Termination Resistor Ampseal Connector (typical)

Illustration 12 g01355248 Illustration 14 g02219254

Engine Speed/Timing Connector

Deutsch Connectors (typical) Table 5

For example, a wire identification of A701-GY(Grey)

The connection of any electrical equipment and

Harness Wire Identification

Configuration Parameters “ Top Engine Limit”” (TEL)

System configuration parameters are parameters

Note: When you are requesting factory passwords,

Note: Factory passwords are required in order to

1. Program “Run Out Control” to “ON” , then

2. Restore the power. After power is restored,

3. Program “Top Engine Limit” to “1800 RPM” .

“ Engine Accel. Rate”” “ Intermediate Engine Speed””

“ High Idle Speed””

“Engine Torque Limit” can be used to limit torque

“ FLS”” (Full Load Setting)

“ FTS”” (Full Torque Setting)

Illustration 20 g00763900 “FTS” is similar to “FLS” . Factory passwords are

“ Air Shutoff”” “ Aux Temp Sensor Installation Status””

“ Maintenance Indicator Mode””

“ Throttle Position Sensor””

“ Coolant Level Sensor””